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Open AccessArticle

Wear Improvement of Tools in the Cold Forging Process for Long Hex Flange Nuts

by Shao-Yi Hsia 1,* and Po-Yueh Shih 2
Department of Mechanical and Automation Engineering, Kao-Yuan University, Kaohsiung 82151, Taiwan
Chong Cheng Fastener Corporation, 69 Da-Shun Rd. Guan-Miau, Tainan 71844, Taiwan
Author to whom correspondence should be addressed.
Academic Editor: Teen-Hang Meen
Materials 2015, 8(10), 6640-6657;
Received: 18 August 2015 / Revised: 16 September 2015 / Accepted: 22 September 2015 / Published: 25 September 2015
(This article belongs to the Special Issue Selected Papers from ICASI 2015)
Cold forging has played a critical role in fasteners and has been widely used in automotive production, manufacturing, aviation and 3C (Computer, Communication, and Consumer electronics). Despite its extensive use in fastener forming and die design, operator experience and trial and error make it subjective and unreliable owing to the difficulty of controlling the development schedule. This study used finite element analysis to establish and simulate wear in automotive repair fastener manufacturing dies based on actual process conditions. The places on a die that wore most quickly were forecast, with the stress levels obtained being substituted into the Archard equation to calculate die wear. A 19.87% improvement in wear optimization occurred by applying the Taguchi quality method to the new design. Additionally, a comparison of actual manufacturing data to simulations revealed a nut forging size error within 2%, thereby demonstrating the accuracy of this theoretical analysis. Finally, SEM micrographs of the worn surfaces on the upper punch indicate that the primary wear mechanism on the cold forging die for long hex flange nuts was adhesive wear. The results can simplify the development schedule, reduce the number of trials and further enhance production quality and die life. View Full-Text
Keywords: cold forging fastener; Archard wear; Taguchi quality method; hex flange nut cold forging fastener; Archard wear; Taguchi quality method; hex flange nut
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Hsia, S.-Y.; Shih, P.-Y. Wear Improvement of Tools in the Cold Forging Process for Long Hex Flange Nuts. Materials 2015, 8, 6640-6657.

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