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The research was financed in the framework of the project: New metal forming technique for producing flanged hollow parts for the mining industry, No. LIDER/1/0003/L-9/17/NCBR/2018. Total cost of the Project: 1197000PLN. The project is financed by the National Center for Research and Development under the 9th edition of the LIDER Program.
This paper presents the modeling of a cold forging process for a rotary sleeve. The process of forging a EN
42CrMo4 steel part was first modeled numerically by the finite element method using simulation software
DEFORM 3D ver. 11.0. After that, the developed forging process was verified by experimental tests carried
out in laboratory conditions with the use of 1:2 scale tools and a material model of aluminum alloy EN AW-
6060. Finite element method (FEM) results demonstrated that rotary sleeves could be formed from tubes by
cold forging. Results of the experimental tests showed, however, that the material inside the hole of the work
piece might not adhere to the surface of the sizing pin. Distributions of strain and stress during the forging
process are determined. Geometrical parameters of forged parts obtained in experimental tests are com-
pliant with the dimensions of forged parts simulated by FEM. In addition, experimental forces of the
forging process show a high agreement with the forces obtained in FEM simulations.
