CASE STUDY ON THE OPTIMUM COLD FORGING PROCESSES OF

CARBON STEEL M10 FLANGE NUT

螺 帽 冷 鍛 製 程 最 佳 化 探 討 - 以 碳 鋼 M10 螺 帽 為 例

國立高雄應用科技大學
精 密 模 具 與 機 械 產 業 研 發 碩 士 外 國 學 生 專 班 98 春 季 班
碩士論文

A Thesis
Submitted to
Institute of Mechanical and Precision Engineering
National Kaohsiung University of Applied Sciences
In Partial Fulfillment of the Requirements
For the Degree of Master of Engineering in
International Industry Research Master Program for Precision
Mold and Die/Mechanical Engineering, Spring 2009

Student: Tran Thai Hong

Advisor: Dr. Yung Chou - Kao

January 2011
Kaohsiung, Taiwan, Republic of China
中華民國一百年一月
 摘要

在 螺 帽 冷鍛 的 過 程, 成 形 負 荷 增 加 直 到 結 束 行 程, 為 了 確 定 最低 成 形
負 荷 值, 針對模具的 角 度 和 深 度 沖 頭進 行最佳 化 設 計, 本 研 究 提 出 了 應 用 有
限 元 素 法（FEM）與 田 口 方 法 以 獲 得 一組 最 佳 參 數, 實 驗 是 規 劃在 L18 之 直
交 表, 最 佳 水 平 的 參 數 確 定 通 過 分 析 信 號 的 雜 訊 比, 透 過 田 口實 驗模 擬 結
果顯示影響成 形 負 荷, 有 效 因 素 是 第 三 沖 頭 的 深 度.

關 鍵 字：冷鍛, 有 限 元 素 法, 田 口 方 法, 成 形 負 荷

ABSTRACT

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 In flange nut cold forging processes, forming load is increasing until end of stroke. In
order to determine lowest forming load value, a set of optimal design factors were investigated
including die angle and depth of punch. This research presents the application of finite element
method (FEM) and Taguchi method in order to acquire a set of optimum parameters. The
experiments were planned in accordance with L 18 orthogonal array. The optimal level of the
parameters was determined through the analysis of signal to noise ratio. The simulation results
indicated that lowest forming load could be achieved through Taguchi experiments, and the
most significant effect factor is that of the depth of punch of the third punch.

Keywords: Cold forging, finite element method, Taguchi method, forming load.

ACKNOWLEDGMENTS

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 I would like to take this opportunity to convey my heartfelt gratitude to my advisor
Dr. Yung - Chou Kao for his outstanding guidance and personal dedication in the course of this
research, above all at the early stage of my master’s study, and for valuable time he spent
during his busy schedule.

I also wish to thank Zu Low Shing Industrial Co., LTD for give me a chance to visit in
order to understand more clearly about my thesis.

I would like to thank to members in my laboratory including 陳錫浴, 曾岳峰, 沈修弘, 陳

宛君, 林明欣, 楊宗儒，趙晟銘, 何俊廷, 文懷柔, 杜順和, 吳清毅, 謝福霖, 廖家偉, 邱子豪
who supported and helped me so much in during my course.

Great thanks to National Kaohsiung University of Applied Sciences (Taiwan) for their
generous scholarship, which allows me to finish my study.

Finally, I wish to thank my family and my friends for their constant encouragement.

Tran Thai Hong

December 2010

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 TABLE OF CONTENTS

ABSTRACT (Chinese).................................................................................................i

ABSTRACT (English)...................................................................................................ii

ACKNOWLEDGEMENTS.......................................................................................iii

TABLE OF CONTENTS...........................................................................................iv

LIST OF FIGURES...................................................................................................vii

LIST OF TABLES......................................................................................................ix

Chapter 01 INTRODUCTION

1.1 Introduction...........................................................................................................1

1.2 Objectives of the research.....................................................................................2

1.3 Method of research..............................................................................................3

1.4 Dissertation organization......................................................................................4

Chapter 02 LITERATURE REVIEW......................................................................5

2.1 Introduction to cold forging process....................................................................5

2.2 Introduction to simulation of the forming process............................................10

2.2.1 Purpose of simulation................................................................................10

2.2.2 Roles and advantages of numerical simulation in the design and optimal

technology..............................................................................................................12

2.3 Applying Taguchi method in cold forging process.............................................14

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Chapter 03 RELATED TECHNOLOGY..............................................................23

3.1 Nut forming process.....................................................................................23

3.2 Solidworks software Overview...................................................................24

3.3 Deform 3D software Overview...................................................................23

3.4 Introduction to Taguchi method...................................................................28

3.4.1 Design process of Taguchi method.........................................................28

Chapter 04 FLANGE NUT GEOMETRY, DIE MODELLING

FINITE ELEMENT ANALYSIS AND TAGUCHI EXPERIMENT.........................33

4.1 M10 flange nut geometry and Die model..........................................................33

4.1.1 Flange nut geometry...............................................................................33

4.1.2 Workpiece volume and height calculation..............................................34

4.1.3 Die primary model..................................................................................35

4.1.4 Tool and die design.................................................................................36

4.2 Flange nut forming processes analysis............................................................41

4.2.1 Stages of flange nut forming process.......................................................41

4.2.2 M10 flange nut simulation process with some initial conditions...........42

4.3 Taguchi analysis of flange nut cold forging.....................................................43

Chapter 05 ANALYSIS OF SIMULATION RESULTS.......................................45

5.1 Analysis of Taguchi experiment simulation.......................................................45

5.1.1 Analysis of optimum of flange nut cold forging process..........................45

5.2 Analysis of flange nut forming processes with optimal factors..........................48

5.2.1 Analysis of pre-form flange nut stress-effective.......................................49

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 5.2.2 Analysis of forming load...........................................................................50
5.2.3 Analysis of Volume...................................................................................55

Chapter 06 RESULTS AND DISCUSSION............................................................56

Chapter 07 CONCLUSION AND FUTURE WORKS

7.1 Conclusion......................................................................................................56

7.2 Future works...................................................................................................56

REFERENCES LIST...................................................................................................57

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 LIST OF FIGURES

Figure 1.1 Flange nut forming stages.............................................................2

Figure 2.1 Typical cold forging parts.............................................................7
Figure 2.2 Procedure of simulation..............................................................11
Figure 3.1 Nut manufacturing procedure.....................................................23
Figure 3.2 A tapping example......................................................................26
Figure 3.3 A drilling example......................................................................27
Figure 3.4 A cogging example.....................................................................27
Figure 3.5 Taguchi experiment flowchart....................................................32
Figure 4.1 Flange nut geometry...................................................................33
Figure 4.2 Flange nut cross-section..............................................................34
Figure 4.3 Scheme of work-piece geometry...............................................34
Figure 4.4 Modeling die set up for flange nut cold forging process............35
Figure 4.5 Top and bottom punch 01...........................................................36
Figure 4.6 Master die 01...............................................................................36
Figure 4.7 Top and bottom punch 02...........................................................37
Figure 4.8 Master die 02...............................................................................37
Figure 4.9 Top and bottom punch 03...........................................................38
Figure 4.10 Master die 03...............................................................................38
Figure 4.11 Top and bottom punch 04...........................................................39
Figure 4.12 Master die 04...............................................................................39
Figure 4.13 Top punch 05..............................................................................40
Figure 4.14 Master die 05...............................................................................40
Figure 4.15 Five stages flange nut cold forging process................................41
Figure 4.16 Second and third top punch depth...............................................44
Figure 4.17 Draft angle of 2, 3 and 4 master die...........................................44
Figure 5.1 Diagram of S/N ratio forming load predicted (dB).....................47
Figure 5.2 Flange nut forming process diagram...........................................48
Figure 5.3 Diagram of stress- effective distribution at first stage................49
Figure 5.4 Diagram of stress- effective distribution at second stage...........49

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Figure 5.5 Diagram of stress- effective distribution at third stage...............49
Figure 5.6 Diagram of stress- effective distribution at fourth stage.............49
Figure 5.7 Diagram of forming load of second stage..................................51
Figure 5.8 Diagram of forming load of third stage.....................................52
Figure 5.9 Diagram of a part of material before is pierced completely......52
Figure 5.10 Diagram of a part of material after is pierced completely.........52
Figure 5.11 Diagram of forming load of fourth stage .................................53
Figure 5.12 Diagram of forming load of piercing stage................................53
Figure 5.13 The finishing flange nut..............................................................54

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 LIST OF TABLES

Table 2.1 The summary of reviewed literature..............................................18

Table 3.1 Typical application of Deform 3D.................................................25
Table 3.2 Orthogonal array L8.......................................................................29
Table 3.3 S/N ratio of Taguchi orthogonal array...........................................31
Table 4.1 Deform 3D simulation parameters.................................................42
Table 4.2 Factors and their levels..................................................................43
Table 5.1 S/N ratio for forming load in flange nut cold forging process.......46
Table 5.2 Mean S/N response table for forming load....................................47
Table 5.3 The optimum factors and levels.....................................................48
Table 5.4 Design of initial factors and optimum factors................................54
Table 5.5 Work-piece volume before and after simulation...........................55

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 Chapter 01

INTRODUCTION

1.1. Introduction

It is well known that cold forging offers good surface with better mechanical properties
in the forged products. Thus, its application is ever increasing to substitute hot or warm
forgings recently. Since the cold forging load is relatively higher or very larger [1] than those
of the other processes, predictions of forming load and tool life are important. Forming load in
cold forging has considerable effects in whole of cold forging process. In cold forging, lower
forming load is expected as small as possible, because high forming load will cause failures,
cracks, shrink, die un-filling or some laps in the final product. Therefore the major focus of this
research is on forming load analysis in order to achieve the smallest load in forming process.
Numerical techniques; especially finite element method (FEM) was used in this study for the
simulation of the forming process.

In cold forging industry, it is necessary to minimize the computation time and effort
depending on the purpose of the simulation as pointed out earlier. Although there are many
simulation programs available, but in this research, FEM modeling approaches were carried
out by using a commercial finite element code, DEFORM-3D software. According to this
study, the simulation results obtained were quite accurate.

In this study, a useful finite element-based approach for predicting the geometric
dimensions of cold forging is presented and five stages flange nut forming (Figure 1.1) was
used for investigation, simultaneously apply Taguchi method [2] in order to optimize input
factors of this cold forging process to obtain the best geometry, and products that have the best
performance characteristics.

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 Figure 1.1: Flange nut forming stages

1.2. Objectives of the Research

The main objective of this research is to study factors affecting flange nut cold forging
processes and simultaneously find out optimum factors to optimize the production of flange nut
with the best quality characteristic. The concrete objectives are as follows:

 In cold forging process, there are many factors influent product forming process. The
typically representations for these factors are such as: friction coefficient [3], forming load,
stress and strain effective and material property, so on. With purpose is to produce the final
product with surface finish without causing crack or lap, so this study used finite element
analysis technology to understand the nut formation process, metal forming process and stress
and strain distribution.

 In addition, the die filling and die contact must be checked in the final stage. The specific
impression on the die cavity is to obtain a near net-shaped component. The volume before
deformation should be very close to the volume after deformation. And this process also would

2
occur on some failures in final product. So this study also research to avoid the errors during
the forming process to achieve the best final product.

 Taguchi method is applied to optimize factors which affect nut forming process in order to
find out which factors have fixed affection for complete product, from that we can apply those
optimum parameters in industrial production to produce the product with the best performance.

 The use of finite element analysis technique for the analysis of the forming simulation of
nuts could save the cost and time. Also in the most cases, numerical methods provide more
flexibility than physical modeling since they allow for quick changes in the tooling design [4].
There also is the task of predicting failure due to unknown stresses by showing problem areas
in material and allowing designers to see all of the theoretical stresses within.

1.3. Method of Research

In this study, 3D CAD software SolidWorks was used to develop nut and forming die
geometries of the 3D model. In addition, Taguchi method was used for die design optimization
in order to achieve nut forming process with combination of geometric parameters of the die.

This research also used finite element software Deform 3D to analyze and simulate nut
forming process, simultaneously combined with Taguchi experimental design method in order
to find out the best factors and their levels.

The research was based on the actual size of flange nut and after that billet geometry
and die geometry of flange nut was constructed by CAD drawings; CAD drawings will be
converted STL file and was imported into Deform 3D software to begin simulation process. In
Deform 3D simulation software, the process parameters were set up in accordance with actual
conditions. After the complete simulation processing, analysis of the simulation results would
be conducted including analysis of the stress - strain distribution of the billet, analysis of die
filling, analysis of the forming load and so on.

Moreover, this research also study about geometry parameters of flange nut and die in
order to understand general geometry parameters of the case, Taguchi method with orthogonal

3
array L18 was used, series of simulation process was run to get the best combination of
parameters; the dimension of the simulation product was compared with initial design
dimension.
1.4 Dissertation Organization

This dissertation consists of seven chapters. Chapter 1 introduces the topic, objective
and method of research. The chapter 2 talks about literature review of background of cold
forging, introduction to cold forging simulation process and brief introduction to the Taguchi
method used in cold forging process. Chapter 3 talks about related technology. It contains
introduction to nut forming process and also mentions the software used for study, these are
Solidworks and Deform 3D software. Chapter 4 discusses flange nut die model and finite
element method analysis. In this chapter flange nut and die geometry has been described, as
well as finite element method has been analyzed clearly. Chapter 5 discusses the analysis of
simulation results of the research. Chapter 6 talks about results and discussions of the research.
The conclusions and the future works, which can be carried out with respect to this research,
have been discussed in Chapter 7.

Chapter 02

4
 LITERATURE REVIEW

The scope of this research is to focus on flange nut forming process in order to develop a
system that can meet the needs of industrial development. And in literature discussion section
of this chapter, literature review process for flange nut will be presented as the following:

2.1 Introduction to cold forging process

2.2 Introduction to simulation of the metal forming process
2.3 Applying Taguchi method in cold forging process

2.1 Introduction to Cold Forging Process.

This review discusses the forging process and different modeling methods that have
been acquired from a variety of technical journals. A complete overview of the details involved
in designing the forging strategies will be provided. Also, highlights of reviews amongst the
latest ongoing research and development in the field of forging will be explored.

A cold forging process is the process that coiled wire at room temperature is precisely
sheared to length, and then moved through a succession of tool and die cavities to displace
working the metal, either larger/smaller in diameter, longer/shorter in the length or to remove
small amounts by trimming or piercing. Metal is forced beyond its yield limit and retains its
altered shape upon removal from the die. The metal is not forced beyond its tensile strength
otherwise fracture would occur. Historically cold forming has been an experienced based
technology, but this is changing as new computer based analytical tools are constantly being
developed.

In a typical cold forging process, the punch was attached on the machine axis and when
punches convert the required force from the machine to the material and provide close
dimensional control on the internal part features. Dies confine and direct the material into the
desired geometry and provide close dimensional control on the external part features.

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 Cold forging can produce metal components to close tolerances and net shape,
eliminating expensive secondary operations like machining. Additionally, parts produced by
this precision forging process can routinely deliver higher properties than machined parts. In the
case of extruded steel parts, mechanical properties can be as much as 40% greater. In fact, as
compared to heat treated steels at the same hardness, cold-forged components produced from
steel wire, rod, and bar permit use of up to 20% higher design yield strengths. Because cold
forging is geared to high volume production and automation, it can be more cost-effective than
alternative metal working processes. Design flexibility, part consolidation, and elimination of
labor intensive secondary operations and heat treatment are among many reasons why cold
forging is chosen. Although cold forging is commonly associated with high-volume
components, it can be successfully utilized in many industrial fields. When other materials
more expensive than steel material are employed, cold forging can be economical at lower
quantities.

When properly designed, forgings can be more cost-effective than metal parts produced
by alternative methods, such as castings, machined bard and plate, weldment, stampings, built
up structures, sheet metal, and other fabricated assemblies. All issues are said above is due to
cold forging had design optimization. Actually, there are many conventional ways to cut costs-
reducing drafts, tolerances, reviewing process options, substituting lower-cost materials,
making property tradeoffs, and more that should be considered to achieve the cost effective
forging. However, optimization of a forging design should be all-inclusive for best economy.
When outside constraints limit the forging design, choosing another alloy or altering the heat
treatment practice can readily meet the increased strength requirements. However, with
castings, the only recourse would be a change in design or configuration.

Applications of cold forging can be found in the automotive, motorbikes, bicycles

and aircraft industries and in the manufacturing of components for electrical field.
Automotive applications can be seen in motion transmission parts, nuts and bolts.
Representative electrical applications are flat-wipe electrical connectors, resistance welding
electrode caps. Figure 2.1 shows some typical cold forging parts.

6
 Fig 2.1: Some of typical cold forging parts [I]

Some of the advantages of cold forging in comparison with the warm, hot forging and
casting are the material savings achieved through precision shapes that require little finishing,
elimination of scrap. Completely contained impressions and extrusion-type metal flow yield
draft-less, close-tolerance components. Production rates are very high with exceptional die life.

While cold forging usually improves mechanical properties, the improvement is not
useful in many common applications and economic advantages remain the primary interest.
The quality of product after cold forging process is high and can meet requirement of
customers. Tool design and manufacturing process design are critical. Beside above
advantages, the using of many materials is also strong point of this method. Almost materials
can be used in cold forging such as: carbon steel, aluminium, stainless steel, alloy steel, brass,

7
copper, bronze and nickel alloys, so on. Material used in cold forging was incessantly
innovated, so material is less expensive, easier-to-process materials options like micro alloyed
steels deliver great economies in forged components such as automotive transmission and
engine parts. Conserving energy by eliminating heat treatment, switching from quenched and
tempered alloy steels to air-cooled micro alloyed grades, saves as much as 15% on connecting
rods, crank shafts, gears, steering arms, and wheel hubs. Also, forgings made from continuous
cast steel on automatic presses can be cost-competitive with ductile-iron parts.

Precision geometry dimension of product in cold forging is one of the standards to

evaluate its technological because it would affect the product quality and characteristics. A
typical example for prediction of geometric dimension for cold forging using the FEM was
studied by B.Y. Jun and his team at al [5] showed this issue. In this study, he developed a
systematic approach for predicting the geometric dimension of cold forging. The approach
employed a rigid-thermoplastic FEM to simulate the forging and an elastic FEM to model both
the elastic deformation of the die and provide a spring back analysis of the work piece. The
mechanical load was applied due to the elastic unloading of the forming load while the thermal
load was applied due to the cooling of the increased forging temperature to room temperature.
This investigation and with support of experience, the proposed approach can be a useful tool
for process design in precision cold forging.

When considering die and punch geometry, a problem appeared here is that how final
product geometry, it is exact or at least it will meet technology requirement? As for this field,
the influence of die shape on the flow deformation of extrusion forging was researched by
Chun-Yin Wu [6]. In this study the influence of various die shapes on extrusion forging
deformation have been analyzed successfully using the FEM. The draft angle and the fillet
radius affect the extrusion load, the boss height, the flange width, the strain and its distribution
and flow deformation at different levels. The results of this study could be expanded to the
design of a more complicated pre-forging die and the planning of the forming process. This
would be of practical benefit to the forging industries.

Pradeep L. Menezes et al [7]. FEM and Deform 3D software have been used to study
the influence of the coefficient of friction on the state of stress by conducting compression

8
tests. This study discovered that the state of stress is strongly influenced by the coefficient of
friction at the interface; the higher the value of the coefficient of friction at the interface, the
greater will be the constraint to plastic flow of the material, and thus the less will be the flow of
material; the coefficient of friction, if the coefficient of friction was controlled properly at the
interface could generate the required state of stress and the flow of material; microstructure
evolution in the work-piece, which depends on the strain rate, depends on the friction at the
die/work-piece interface.

Beside that, some different process conditions also effect to product formed process
such as: the stress-strain relationship of the billet and die material, etc. But stress on die could
be reduced by improving the die and tool design. In this aspect, a research into the effects of
corner radii and part orientation on stress distribution of cold forging dies by Ahmad
Baharuddin Abdullah [8] showed that the changing in corner radius can affect the stress level
generated on the die. Where there is a scope that the stress level will drop even though the
corner radius is increasing. After studied twenty-one different design of dies, the optimal
design is the horizontally oriented die with corner radius of 3 mm. This design not only
induced in lowest stress level during the forging operation, but also causing minimum
deformation on die, where the structure of the die can return to its original position after
removing the load exerted.

There are also some studies that research on effects of design variables (i.e. die corner
radii, die height difference, surplus of specimen, and aspect ratio of specimen) for a given
profile of cold forging part. However, various profiles of forging parts may cause the variation
of maximum effective strain, peak load and die fill, and it is impossible to take all the parts into
consideration. As for the complex shapes of parts, a new definition of complexity factor is
proposed in view of various geometrical parameters of a part in cold forging process
researched by Toshihiko Mori et at [9]. In this research, various geometric profiles of parts
have been discussed, the relationship of complexity factor and maximum effective strain, peak
load and die fill were investigated by FEM. In comparison with the existing definition of
complexity factor, the newly proposed complexity factor could reflect the forging difficulty
more reasonably. The results of this study were drawn that based on the existing complexity
factor introduced by other researchers, a new definition was proposed, which depicted the

9
complexity factor in terms of geometry of the part. Taking a forging part made by backward-
forward combined extrusion for example, complexity factor was determined by varying the
profiles of the part. FE simulations were carried out to help researcher exploring the
relationship between complexity factor and maximum effective strain, peak load and die fill.
According to this paper, the definition of complexity factors SP, ST, ST’, ST’’ proposed in this
research, among which SP was the easiest for calculation and it was the most desirable to reflect
forging difficulty.

Through consideration of related papers, this research realized that beside advantages
of cold forging process then these studies showed some factors affect cold forging process, so
they need to be considered to restrict their badly affection to process.

2.2 Introduction to Simulation of the Cold Forging Process

2.2.1 Purpose of simulation.

The simulation method for purposes of at the research that analyzes and explains
the processes occurred when the material was formed. Simulation results show more clearly,
thereby further the understanding, corrective comments to contribute to finding appropriate
technology solutions in the production process. In metal forming, process simulation is used to
predict metal flow, strain, temperature distribution, stress, tool forces and potential sources of
defects and failures. In some cases, it is even possible to predict product microstructure and
properties as well as elastic recovery and residual stresses. The procedure of simulation is
showed as figure 2.2

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 Construction of Die and
Work piece Geometry

Create Mesh for Tool and

Work piece

Select Material, Setting Boundary

Condition, Contact Condition, etc.

Conduct Simulation

Yes Evaluation of
End
Simulation
Simulation
Results

No
Apply Simulation
Update Die or Work piece Results to
Geometry Production Practice

Re-meshing

Adjust Boundary
Conditions, etc.

Figure 2.2: Procedure of simulation

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 2.2.2 Roles and Advantages of Numerical Simulation in The Design and Optimal
Technology
When performing simulation, design processes and modification are conducted on the
computer. Starting from the idea or product samples, product model is built on the computer
then modifying the parameters, process conditions are done directly through user-computer
interface in order to optimize technology from that considerable reducing time and cost. The
simulation also has contributed to improving product quality and allowing application of new
materials.

According to traditional manufacturing methods, in order to produce a product then

after designed product, trial manufacturing was conducted. These stages usually have to work
many times until producing the completely product. With this method, design and fabrication
the die must be repetitively conducted many times, causing of time and cost wasting. But with
numerical simulation, the entire processes from design to optimization, correction parameters
and conditions have been done on the computer. Therefore it will not take much time and
finance, increasing computing efficiency, improving product quality and competitive.
Moreover, using simulation would be possible to:

 Determine material properties such as grain size

 Determine local hardness
 Predict material damage
 Predict phase changes and composition
 Simulate the influence of material selection

As simulation allows to capture behaviour that cannot be readily measured it would

provide deeper insight into manufacturing process. A simulation of the cold forging process in
fastener manufacture which was researched by Umut İnce et at [10] pointed out this aspect
quite clearly. This research used finite element method to investigate laps formation and
forging loads. A standard hexagon head bolt was produced in two-stations by a cold forging
mechanical press. The bolt was produced with the forging sequence and bolt was sectioned and
polished in order to observe the laps formation microscopically. The results showed that

12
numerical simulation method is very useful tool in order to determine the faulty designs in the
cold forging sequence.
The application of computer aided methods in generally forming processes and partly
today especially important precision or net shape forming processes involves:

 The conversion of the assembly-ready part geometry into a formable geometry

 The preliminary design of tools/dies necessary to perform the operations used for
forming the parts
 The analysis and optimisation of each forming operation and the associated tools
design, to reduce process development, decrease times of trial and error.
 Manufacturing of tools and dies by CNC (computer numerical control) milling or
by EDM (electrical discharge machining) or another similar technology also need to
be conducted in this way.

The ascertaining of process-specific factors in production engineering by means of

process simulation serves the efficient manufacture of products of specified properties. Three
objectives are emphasised:

 Review of the feasibility of an existing concept for the manufacture of a product

 Assessment of product characteristic
 Enhancement of understanding as to what really affects in a process for the purpose
of optimising the manufacturing technique

To achieve these goals, however, it only makes sense to use process simulation if this is
more economical in the long run than experimental repetition of the actual process.

2.3 Applying Taguchi Method in Cold Forging Process

The optimization of process parameters requires a systematic methodological approach

by using experimental methods and mathematical or statistical models [11]. Taguchi method is
used to optimize the performance characteristics of process parameters, which is proved to be a
powerful tool that differs from traditional practices [12]. This approach can economically
satisfy the needs of problem solving and design optimization with less number of experiments

13
without the need for process model developments. Thus, it is possible to reduce time and cost
for the experimental investigations. The original Taguchi method is designed to optimize a
single performance characteristic. However, most of the products have multiple performance
characteristics [13], and hence, there is a need to obtain a single optimal process parameters
setting that can be used to produce the products with optimum or near optimum characteristics.
In the Taguchi method, in combining the experimental design techniques with quality loss
consideration, is conventionally used for off-line quality control [14]. Three sequential stages
will be included for applying Taguchi method into optimizing a product or process: (1) System
design, (2) Parameter design, and (3) Tolerance design [15]. Taguchi suggested that we can use
the quadratic loss function to measure the loss for the departure of the target. The optimum
parameter conditions, which makes the product to be more ‘robust’ for the environment factors
and to be more close to the target, is then determined by performing the parameter design.
Parameter design is also commonly referred to as ‘robust design’. Taguchi’s parameter design
can be divided into two classes for system’s architecture:
 Static and characteristics.
 Dynamic characteristics.

These two classes differ primarily in that the latter employs the signal factor and the
former does not. In Taguchi’s dynamic method, there are three criterions of the performance:
(1) Sensitivity; (2) Linearity and (3) Variability. To measure these three criterions, Taguchi
suggested two indexes (Fowlkes and Creveling, 1995; Peace, 1993; Phadke, 1989) to
determine the optimum parameter condition and, the two indexes can be defined as the S/N
ratio (Hong, 1996) and sensitivity (S):

Moreover, the Taguchi method used a generic signal-to-noise (S/N) ratio to quantify the
present variation. Depending on the particular type of characteristics involved, different S/N
ratios are applicable, including “lower is better” (LB), “nominal is best” (NB) or“higher is
better”(HB). The S/N ratio for the LB characteristics of the current cold forging process is
given by William and Creveling [16]:

14
 Equation (1)

where n is the number of simulation repetitions under the same design parameter
conditions, indicates the measured results and subscript indicates the number of design
parameters arranged in the Taguchi orthogonal array (OA).

At research on parametric optimization of ultrasonic machining of co-based super alloy,

Vinod Kumar and J. S. Khamba et at [17] applied the Taguchi quality loss function in order to
optimize the multiple quality characteristics. The optimization of the process parameters in the
ultrasonic machining of stellite 6 has been done by applying the Taguchi multi-objective
optimization technique. The quality characteristics experimental values of material removal
rate and tool wear rate at optimum conditions have been improved considerably in comparison
to initial parameter settings of the experiment.

In the field of engineering machining, optimization of turning parameters for surface

roughness and tool life based on the Taguchi method Ahmet Hascalık & Ulas Caydas et at [18]
used L9 orthogonal array experimental in order to identify the optimum surface roughness and
tool life performance with a particular combination of cutting parameters in turning titanium
alloy. Simultaneously also conducting confirmation tests is to validate conclusions drawn
during the analysis phase. Once the optimal level of the process parameters is selected, the
final step is to predict and verify the improvement of the performance characteristics using the
optimal level of the process parameters. And the research showed that based on the analysis of
variance (ANOVA) results, the highly effective parameters on both the surface roughness and
tool life were determined. The feed rate parameter was the main factor that had the highest
importance on the surface roughness and this factor was about 1.72 times more important than
the second ranking factor (depth of cut). The tool life was affected strongly by the cutting
speed (73.69%), whereas the feed rate and depth of cut had a significant statistical influence.
The improvement of the surface roughness from the initial machining parameters to the
optimal machining parameters was about 24.4%, whereas the tool life is improved by 33.5%.

15
 When researching on die casting process, C.P Syrcos et at [19], employed Taguchi
method with purpose is optimize some parameters which affecting the quality characteristics
those are piston velocity, type and quantity of die lubricant, size and shape of gate, die vating
system design, metal temperature, filling time and hydraulic pressure, so on, the material was
chosen in this case that was AlSi 9Cu13 aluminium alloy. Results of this study showed that metal
temperature, piston velocity, time filling and hydraulic pressure were the influential parameters
affecting the casting density of AlSi 9Cu13 aluminium alloy castings. The predicted range of
optimum casting density was 2.749g/cm3 < casting density < 2.7525g/cm3

Experimental investigation on flow-forming of AA6061 alloy - A Taguchi approach

M. Joseph Davidsona, K. Balasubramanianb, and G.R.N. Tagorea et at [20], applied Taguchi
experiment with L9 orthogonal array were used to investigate on flow-forming of AA6061
alloy. The purpose of this research is to optimize process parameters and identify the optimal
combination of factors for the desired responses in order to produce seamless tubes of
maximum percentage elongation ratio (%D) and tube had strength well with minimum or no
surface damage. The present investigation was performed on a four-axis CNC flow-forming
machine with a single roller. Results of this study was drawn that the variables affecting the
percentage elongation according to their relative significant were the depth of cut, the speed of
the mandrel and the feed, respectively. Simultaneously it has been shown that, forming
parameters set up at their optimum levels could ensure significant improvement in the response
function.

Methodology of pre-form design considering workability in metal forming by the

artificial neural network, D.C. KO and his group et at [21], suggested a new method of pre-
form design in multi-stage metal forming processes considering workability limited by ductile
fracture. Using the finite element analysis combined with ductile fracture criterion workability
had been predicted the Artificial Neural Network (ANN) and Taguchi method had been
implemented for minimizing an objective function relevant to the forming process. For purpose
was to optimize ductile fracture and forming load in the final product. This research conducted
two process designs for ductile fracture and forming load. Results of research drawn that the
load of process design II was lower than that of process design I, the maximum difference in
load was little, about 40 KN and this load difference was observed in the pre-forming

16
operation. Considering both workability and forming load, therefore, it was concluded that the
process design I could be considered as the optimal process design, because process design I
indicated that the probability of failure in the product was extremely low.

Besides that, the combined robust parameter and tolerance design using orthogonal
arrays by A. Jeang et at [22] showed that in order to reduce the number of computer simulation
runs required for statistical analysis, powerful statistical tools such as the techniques of
designed experiments should be adopted. There are various approaches for studying specific
experimental design such as build–test–fix, one factor at a time, full factorial experiments, and
orthogonal array experiments. This research showed the disadvantages and advantages of each
approach but one of them is orthogonal array experiment has more advantages. That is a
method of setting up experiments that require only a fraction of the experiments required for a
full factorial combination. The treatment combinations were chosen to provide sufficient
information to determine the factor effects. To identify important input variables effectively,
efficient methods such as orthogonal array experiments were used. In this study, a Monte Carlo
simulation was adopted; finally, an assembly problem demonstrated the approach and the
results revealed that the critical and optimal parameter and tolerance values could be
determined effectively with less experimental. The design strategy presented could be applied
to find a set of key factors from a large number of input factors to focus on before detailed
design, particularly, in the earlier stage of planning and design.

Taguchi method truly is the important contribution in many industrial fields, using
Taguchi method is both saving cost, time and achieving quality or process characteristic. Due
to its advantages and affections, so this method was applied widely in production industry.

17
 Table 2.1: The summary of the reviewed literature

Paper Title Author Main Research

A finite element analysis This research used Mechanical
Conor Mc Cormack, and
of cold-forging dies using desktop and Deform 3D to design and
John Monaghan
two and three dimensional analysis hexagonal shape on the head
2001
models of a bolt to predict the level of these
[1] stresses during the forging operation.
M.S. Joun, H.G. Moon, Investigated in detail the effects of
Effects of friction laws on I.S. Choi, M.C. Lee, B.Y. friction laws and friction conditions
metal forming processes Jun on finite element predictions.
[3] 2007
Predictive methods and K. K. Tong, C. S. Goh, Using ANSYS/LSDYNA and
improvements in die life M. W. Fu, T. Muramatsu DEFORM to predict stress in
for cold forging and M. S. Yong production die and provide a
[4] 2008 systematic study to reduce the stress
in tool.
Prediction of geometric B.Y. Jun, S.M. Kang Using finite element-based approach
dimensions for cold M.C. Lee, R.H. Park and for predicting the geometric
forgings using the finite M.S. Joun dimensions of cold forging and
element method 2005 elastic deformation of the die,
[5] springback of the work-piece, and
thermal contraction of the workpiece.
The influence of die shape Chun-Yin Wu and Yuan- Using the finite element method and
on the flow deformation of Chuan Hsu the experimental approach to analyze
extrusion forging 2001 comprehensively the effects of the die
[6] shape with different draft angles and
fillet radii on the extrusion forging
deformation.

18
Influence of friction Pradeep L. Menezes, K. Finite element method and Deform
during forming processes- Kumar, Kishore Satish 3D has been used to study the
a study using a numerical and V. Kailas influence of the coefficient of friction
simulation technique 2007 on the state of stress
[7]
The effect of corner radii Ahmad Baharuddin Research used FEA tools and
and part orientation on Abdullah, Kam Shwu COSMOSWorks in Solidworks
stress distribution of cold Ling and Zahurin Samad software to investigate the effect of
forging die. 2008 corner radius of the die and cavity
[8] orientation on resulted stress.
A new definition of Toshihiko Mori and Research based on evaluations of
complexity factor of cold Suyang Li strain, load and fulfillment of material
forging process 2007 in die cavity obtained by FEM in cold
[9] forging thereby take form a new
definition of complexity factor.
Simulation of the cold Umut İnce, Mustafa This research investigates two
forging process in fastener Güdenb. different examples of the applications
manufacture 2008 of the finite element analysis in the
[10] cold forging processes used to
produce fasteners.

19
In additional, some papers of Taguchi design experiments are also listed as reference literature
as below.

Paper Title Author Main Research

Mathematical, statistical and Sh. Givargis, This research used SPSS, Statistical
neural models capable of and H. Karimi software and Excel along with
predicting LA,max for the 2008 mathematical logarithmic, statistical
Tehran–Karaj express train linear regression, and neural
[11] network models capable of
predicting maximum A-weighed
noise level for the Tehran–Karaj
express train.
Optimizing multiple quality Lung Kwang Pan, Che Taguchi method-based Grey
characteristics via Taguchi Chung Wang, Shien analysis was used to investigate
method-based Grey analysis Long Wei and Hai Feng multiple quality characteristics of
[13] Sher Nd:YAG laser welded titanium
2006 alloy plates
Applying Taguchi’s off-line I.H. Ibrahim E.Y.K. Ng, This study two statistical methods:
quality control method and and K.W.L. Wong the Taguchi Method and the
ANOVA on the 2007 Analysis of Variance (ANOVA) are
maneuverability of the F-5E used to evaluate airflow quality
intake. through the intake via fighter
[14] aircraft maneuvers
Parametric optimization of Vinod Kumar and J. S.
This paper outlines the
ultrasonic machining of Khamba
effectiveness of the ultrasonic
co-based super alloy
2009 machining of stellite 6 in terms of
[17]
tool wear rate of the tool used and
the material removal rate of work
piece produced.

Optimization of turning Ahmet Hascalık and Ulas The effect and optimization of

20
parameters for surface Caydas machining parameters on
roughness and tool life 2007 surface roughness and tool life
based on the Taguchi in a turning operation was
method. [18] investigated by using the
Taguchi method.

Die casting process G. P. Syrcos This paper analyzes various

optimization using Taguchi 2003 significant process parameters
methods. of the die casting method of
[19] AlSi9Cu13 aluminum alloy.
Experimental investigation
M. Joseph Davidson, The influence of the various
on flow-forming of AA6061
K. Balasubramanian and flow-forming process
alloy—A Taguchi approach
G.R.N. Tagore 2007 parameters such as: speed of
[20]
the mandrel, the depth of cut
and the feed on the percentage
elongation (%D) has been
analyzed.
Methodology of pre-form
D.C.KO, D.H. Kim, B.M. This study suggests a new
design considering
Kim, and J.C. Choi method of pre-form design in
workability in metal
1999 multi-stage metal forming
forming by the artificial
processes considering
neural network
workability limited by ductile
[21]
fracture, simultaneously using
the finite element analysis
combined with ductile fracture
criterion, workability has been
predicted.

21
Combined Robust Parameter Jeang and C.-L. Chang
Monte Carlo simulation,
and Tolerance Design Using
2002 orthogonal array experiments,
Orthogonal Arrays
and statistical analysis was
[22]
used in this study in order to
investigate the combined
impact of assigned parameters
and tolerance values to
improve quality and cost
reduction of a product.

22
 Chapter 03

RELATED TECHNOLOGY
3.1 Nut Forming Process

Nowadays, nut general speaking and flange nut say in private are most widely used in
many industry fields such as: Automobile, aerospace, electricity, so on. Nut manufacturing
method was used long time ago but with low productivity. When high-speed nut forming
machine has applied in nut manufacturing technology, then the product productivity have been
increased considerable. The high-speed nut former as proposed in this particular proposal,
could produce almost all kinds of nuts including general type nut, flange nut, prevailing torque
type nut, kepi nut, etc. The nut manufacturing process is presented as flow chart.

Figure 3.1: Nut manufacturing procedure

23
3.2 Solidworks Software Overview

Solidworks software is a 3D mechanical CAD program that runs on Microsoft

Windows. This software allows the designers design, construct, and animation of parts and
equipment assemblies. SolidWorks is a parasolid-based solid modeler, and utilizes a parametric
feature-based approach to create models and assemblies. Parameters refer to constraints whose
values determine the shape or geometry of the model or assembly. Parameters can be either
numeric parameters, such as line lengths or circle diameters, or geometric parameters, such as
tangent, parallel, concentric, horizontal or vertical, etc. Numeric parameters can be associated
with each other through the use of relations which allow them to capture design intent.

3.3 Deform 3D Software Overview

Deform is a simulative software based on the finite element method, deform has proven
to be accurate and robust in industrial application for more than two decades. Among the finite
element method simulation software, deform is the most well-known and widely used. Deform
enables designers to analyze metal forming, heat treatment, machining and mechanical joining
processes on the computer rather than the shop floor using trial and error. Process simulation
using Deform has been instrumental in cost, quality and delivery improvements at leading
companies for two decades. The simulation process is conducted on a computer, no need to
have real specimens or tool. On the numerical side, the system featured a new mesh generator
for improved run times, increased robustness, and accuracy. This revolutionary tool allows
engineers to:

 Reduce the need for costly shop floor trials and redesign of tooling and
processes.
 Expose engineers most imagination and creation.
 Improve tool and die design to reduce production and material costs.
 Shorten lead time in bringing a new product to market.

Deform has, therefore, some advantages following below:

24
  Deform is tailored for deformation modeling.
 User friendly and ready to use graphical user interface provides easy data
preparation and analysis
 Fully automatic, optimized remeshing system tailored for large deformation
problems.

There are some Deform packages and applications such as: Deform 2D, Deform 3D,
Deform F2, Deform F3, Deform HT. Among them deform 3D is a powerful process simulation
system designed to analyze the three-dimensional flow of complex metal forming processes.
Deform-3D is a practical and efficient tool to predict the material flow in industrial forming
operations without the cost and delay of shop trials. Typical applications include:

Forging Machining Rolling

Extrusion Heading Drawing

Cogging Compaction Upsetting

Table 3.1: Typical application of Deform 3D

This research mainly used Deform 3D software to simulate, predict flange nut forming
process, deformation process as well as forming load, stress and strain effective and velocity.
The figures below show some deform applications in practical manufacturing industry.

25
Figure3.2: A Tapping Example [II]

26
Figure 3.3: A Drilling Example [III]

Figure 3.4: A Cogging Example [IV]

27
3.4 Introduction to Taguchi Method
3.4.1 Design process of Taguchi method

The Taguchi method involves with reducing the variation in a process through robust
design of experiments. The overall objective of the method is to produce high quality product
at low cost for the manufacturer. Taguchi developed a method for designing experiments to
investigate how different parameters affect the mean and variance of a process performance
characteristic that defines how well the process is functioning. The experimental design
proposed by Taguchi involves using orthogonal arrays to organize the parameters affecting the
process and the levels at which they should be changed. Instead of having to test all possible
combinations like the factorial design, the Taguchi method tests pairs of combinations. This
allows of the collection of the necessary data to determine which factors most affect product
quality with a minimum amount of experimentation, thus saving time and resources. Taguchi
method is best used when there are an intermediate number of variables, few interactions
between variables, and when only a few variables contribute significantly. Following are some
basic steps of Taguchi method

 Step 1: Identify quality characteristics:

The beginning of experiment, this method need to define the process objectives
or a target values for a performance measure of the process; for example, forming load,
temperature or quality so on. The goal of a process may also be a minimum or
maximum; for example, the goal may be to minimize forming load. The deviation in
the performance characteristic from the target value is used to define the loss function
for the process.

 Step 2: Determine the design parameters affecting the process:

Parameters are variables within the process that affect the performance measure
such as temperatures, pressures, so on, that can be easily controlled. The number of
levels that the parameters should be varied then must be specified. For example, a
temperature might be varied to a low and high value.

28
Step 3: Determine orthogonal arrays:

Orthogonal array is chosen based on the number of parameters and the levels of
variation for each parameter. For example, for four control factors and each factor has
two levels, so there are eight combinations in Taguchi experiment and the orthogonal
array L8(42) is used for this case.

Experiment Factor 1 Factor 2 Factor3 Factor4

1 1 1 1 1
2 1 1 1 2
3 1 2 2 1
4 1 2 2 2
5 2 1 2 1
6 2 1 2 2
7 2 2 1 1
8 2 2 1 2

Table 3.2: Orthogonal array L8 (42)

 Step 4: Conducting the experiments and record results:

After the factors are set completely then the experiments will be conducted.
After the experiments run finishing, we can measure the parameters and experiment
data.

 Step 5: Data analysis:

Complete data analysis to determine the effect of the different parameters on the
performance measure.

 Signal-to-noise: To determine the effect each variable has on the output,

the signal-to-noise ratio, or the S/N number, needs to be calculated for
each experiment conducted. Depending on output quality characteristic
that S/N ratio has three common kinds of S/N as below:

29
 1. Smaller the better:

Equation (2)

Where, S/N: Signal to noise ratio, n: Number of experiments

yi: Experimental values

2. Larger the better:

Equation (3)

Where, S/N: Signal to noise ratio, n: Number of experiments

yi: Experimental values

3. Nominal the best

Equation (4)

Where, S/N: Signal to noise ratio, n: Number of experiments

yi: Experimental values, m: Target value of result

From signal to noise analyzing, the results can be estimated to find out the best product quality
or process through making tabular below:

Experiment Factor 1 Factor 2 Factor 3 Factor 4 S/N

1 1 1 1 1 SN1

30
 2 1 1 1 2 SN2
3 1 2 2 1 SN3
4 1 2 2 2 SN4
5 2 1 2 1 SN5
6 2 1 2 2 SN6
7 2 2 1 1 SN7
8 2 2 1 2 SN8

Table 3.3: Taguchi orthogonal array L8

In order to understand more clearly about this method, this research applied Taguchi
experiment and the experiment will be conducted at back chapter.

 Step 6: Confirmation experiment

Running the experiments at the optimum condition is the final necessary step. So
the process will be able to find out the best process or product quality.

Whole of Taguchi experiment processes are summarized as flow chart below:

Identify the factors

Identify the conditions

31
 Identify control and
noise factors

Identify orthogonal
array

Define the data analysis

procedure

Run experiments

Analyze the data

Predict the product or

process quality

Validation experiment

Figure 3.4: Taguchi experiment flow chart

Chapter 04

32
 FLANGE NUT GEOMETRY, DIE MODELLING, FINITE ELEMENT
ANALYSIS AND TAGUCHI EXPERIMENT
4.1 M10 Flange Nut Geometry and Die Model
4.1.1 Flange Nut Geometry

Figure 4.1: Flange nut geometry

4.1.2 Work-piece Volume and Height Calculation

From M10 flange nut geometry, its volume will be value of 1616.74(mm3)

33
So initial work-piece volume can be calculated as below

Work-piece Volume = Nut volume + pierced part volume

= 1616.74 + 138.15 =1754.89 (mm3)

Height of work-piece is derived: h = work-piece volume/ work-piece section

= 1754.89/ (72*pi) = 11.4(mm)

Pierced part volume

Figure 4.2: Flange nut cross-section

Figure 4.3: Scheme of work-piece geometry

4.1.3 Die Primary Model

34
 Figure 4.4: Modeling die set up for flange nut cold forging process

4.1.4 Tool and Die Design

35
 Process 1:

Top punch

Work-piece

Bottom punch

Figure 4.5: Top and bottom punch 1

Figure 4.6: Master die 1

 Process 2:

Top punch
36
 Work-piece

Bottom punch

Figure 4.7: Top and bottom punch 2

Figure 4.8: Master die 2

 Process 3

Top punch

Work-piece

37
 Bottom punch

Figure 4.9: Top and bottom punch 3

Figure 4.10: Master die 3

 Process 4

Top punch

Work-piece

38
 Bottom punch

Figure 4.11: Top and bottom punch 4

Figure 4.12: Master die 4

 Process 5

Top punch

39
 Work-piece

Figure 4.13: Top punch 5

Figure 4.14: Master die 5

4.2 Flange Nut Forming Processes Analysis

4.2.1 Stages of Flange Nut Forming Process:

Flange nut cold forging process was divided into five stages as figure 4.15
below:

40
 Figure 4.15: Five stages of flange nut cold forging process

4.2.2 M10 Flange Nut Simulation Process with Some Initial Conditions

In this study, M10 flange nut forming process mainly is produced the following
basic assumptions:

41
  Forming process is cold forging so die temperature and work-piece
temperature is at 200C.
 Forming simulation process is conducted with constant friction coefficient
law.
 Work-piece is set to rigid-plastic body, as well as has isotropic and
homogeneous. While die and punch is set to rigid body.

Table 4.1: DEFORM 3D simulation parameters

Items Setting

Material AISI1010

Temperature 200C
First top punch 300 mm/sec
First low punch 0 mm/sec
Second top punch 300 mm/sec
Second low punch 300 mm/sec
Third top punch 300 mm/sec
Die speed Third low punch 300 mm/sec
Fourth top punch 300 mm/sec
Fourth low punch 300 mm/sec
Fifth top punch 300 mm/sec
Constant Friction Coefficient m = 0.08

Number of meshes of work-piece 100000

4.3 Taguchi Analysis of Flange Nut Cold Forging

Flange nut cold forging process experienced five stages, which correspondent with every
stages has different forming load. But in simulation process, this research discovered forming

42
load is larger at three preform stages. So this research only focuses on research forming load at
preform stages as well as factors effect to forming load. The factors and their level like as
Table 4.2

Table 4.2: Factors and their levels

Level
Symbol Level 1 Level 2 Level 3
Factor
Second master die draft
A 0 0.6 ---
angle A2 (Degree)
Third master die draft
B 0 0.6 1.15
angle A3(Degree)
Fourth master die draft
C 0 0.6 1.15
angle A4(Degree)
Second punch depth
D 2 2.4 2.8
d2 (mm)
Third punch depth
E 3.2 3.6 4
d3 (mm)

According to Taguchi experiment for five factors and three levels for the factors B, C,
D, E and two levels for factors A were specified in flange nut cold forging process.
Accordingly, the experimental trials were arranged in an L 18 Taguchi orthogonal array. The
punches and master dies geometry are changed for optimization as below:

43
 Figure 4.16: Second and third top punch depth

0°

Figure 4.17: Draft angle of 2, 3 and 4 master die

Chapter 05
ANALYSIS OF SIMULATION RESULTS

5.1 Analysis of Simulation Taguchi Experiment

5.1.1 Analysis of Optimum of Flange Nut Cold Forging Process

As mentioned earlier, there are three categories of performance characteristics; those are
the smaller-the-better, the larger-the-better, and the nominal-the-better. To obtain optimal

44
process performance and product quality, the smaller-the-better performance characteristic for
forming load should be taken for obtaining optimal process performance in this research.

Table 5.1 shows the experimental results for forming load and the corresponding S/N ratio
using Eq.(2). Since the experimental design is orthogonal, it is then possible to separate out the
effect of each design parameter at different levels. For example, the mean S/N ratio for the first
draft angle at levels 1 and 2 can be calculated by averaging the S/N ratios for the experiments
1–9 and 10–18, respectively. The mean S/N ratio for each level of the other design parameters
can be computed in the similar manner. The mean S/N ratio for each level of the designed
parameters is summarized and called the mean S/N response table for forming load is showed
at table 5.2. In addition, the total mean S/N ratio for the eighteen experiments is also calculated
and listed in table 5.2. Figure 5.1 shows the mean S/N ratio graph for forming load. The S/N
ratio corresponds to the smaller variance of the output characteristics. From also figure 5.1,
with the smaller-the-better performance characteristic for forming load then the analysis of
optimal factors are: A2, B3, C1, D2 and E1.

Table 5.1: S/N ratio for forming load in flange nut cold forging process

A B C D E Loading(N) S/N ratio

Experiment

1 1 1 1 1 1 90460.62 -99.129191
2 1 1 2 2 2 103795.71 -100.323588
3 1 1 3 3 3 155286.01 -103.822646
4 1 2 1 1 2 94793.39 -99.535561

45
 5 1 2 2 2 3 135639.68 -102.647735
6 1 2 3 3 1 109010.82 -100.749392
7 1 3 1 2 1 93755.57 -99.439941
8 1 3 2 3 2 100315.68 -100.027376
9 1 3 3 1 3 95980.68 -99.643676
10 2 1 1 3 3 95114.04 -99.564892
11 2 1 2 1 1 105845.44 -100.493443
12 2 1 3 2 2 111120.05 -100.915848
13 2 2 1 2 3 94743.01 -99.5309435
14 2 2 2 3 1 83468.53 -98.430455
15 2 2 3 1 2 142703.95 -103.088719
16 2 3 1 3 2 130410.96 -102.306281
17 2 3 2 1 3 98753.52 -99.891051
18 2 3 3 2 1 87399.34 -98.830163

Mean of total sum 1928597 -1808.370902

Table 5.2: Mean S/N response table for forming load

Factor
Level
A B C D E

Level 1 -100.5910 -100.7082 -99.9178 -100.2969 -99.5120

Level 2 -100.3627 -100.6638 -100.3022 -100.2813 -101.0328

46
 Level 3 --- -100.0230 -101.1750 -100.8168 -100.8501
Effect 0.2283 0.6852 1.2572 0.5355 1.5208

Rank 5 3 2 4 1

Figure 5.1: Diagram of S/N ratio forming load predicted (dB)

From analysis results and graphs, the optimum factors and their levels are showed in Table 5.3
as below.

Table 5.3: The optimum factors and levels

Factor Second master Third master Fourth master Second punch Third punch
die draft angle die draft angle die draft angle depth depth

Level A2 B3 C1 D2 E1

47
 0.60 1.150 00 2.8mm 3.2mm

After analysis of results then this research conducted running the experiment with the
optimal factors as table above, and the result of simulation process gets forming load value of
73309.39N. This value is less than 10159.14N compare with the smallest value of all
experiments above. Also table 5.2 above, this research shows that, factor E has most affection
for flange nut forming process, following for factors of C, B, D and A, respectively.

5.2 Analysis of Flange Nut Forming Processes with Optimal Factors

Flange nut forming process experience five stages including four pre-form stages and a
piercing stage to complete flange nut forming process. The initial four stages of this process
mainly focus on forming outside geometry of flange nut, simultaneously punch a part of its
inside hole depth in order to make intermediate step for the final stage. The final stage is
piercing step, at this step whole of material inside the hole is pierced completely in order to
form inside hole of flange nut. The figure 5.2 below shows those steps above.

Figure 5.2: Flange nut forming

process diagram

5.2.1 Analysis of Pre-form Flange Nut Stress-effective

48
 Figure 5.3: Diagram of stress-effective Figure 5.4: Diagram of stress- effective
distribution at first stage distribution at second stage

Figure 5.5: Diagram of stress-effective Figure 5.6: Diagram of stress-effective

distribution at third stage distribution at fourth stage
From the diagrams of stress-effective above, stress distribution from second to fourth pre-
form stage are larger than other stages, this stress contribution is focus on almost flange nut

49
body and has the value of more than 99Mpa, this is due to flange nut sustained heavy punch
force from top punch causing large stress, and because of friction coefficient is high, so it is
necessary to reduce friction coefficient in order to decrease stress effective

5.2.2 Analysis of Forming Load

17108.54N

Figure 5.6: Diagram of forming load of first stage

At this stage, forming load gradually increases to the end of the stage then forming load
achieved the largest value is 17108.54N and this value is not large because the deformation at
this stage is not much.

50
 54652.62N

Figure 5.7: Diagram of forming load of second stage

This stage loading is larger than the previous about 37544.08N, because work-piece at this
stage is more deformation and the process start punching inside hole. Maximum loading of this
process attains at the end of stage and get the value of 54652.62N as figure 5.7.

Also, figure 5.8 below shows forming load of third stage, at this process, loading get
largest value of whole of stages is 73309.39N. Because work-piece has been at most deformed.
Additional, maximum loading reaches at the end of process, and loading increased uniformly

since work-piece started deforming until the end of the process, simultaneously load also
uniformly distributed over flange nut body. At fourth stage, forming load as figure 5.11, this is
the stage where flange nut outside geometry is formed completely. Forming load gets the
largest value of 56021.16N at final step of process.

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 73309.39N

Figure 5.8: Diagram of forming load of third stage

At the final stage of process, flange nut almost is formed completely with outside geometry
and inside hole. But this stage loading is really not large because top punch only pierces
redundant material without causing deformation. Figure 5.9 below shows a part of material
would be pierced at final process. Loading would gradually increase and come to step 98,
loading achieves largest value of 8046.28N and after that loading would slightly decrease to
final step as figure 5.12

Figure 5.9: Diagram of a part of material Figure 5.10: Diagram of a part of material
before is pierced completely after is pierced

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56021.16N
 56021.16N

Figure 5.11: Diagram of forming load of fourth stage

8046.28N

53
 Figure 5.12: Diagram of forming load of piercing stage
From analysis of forming load above, this research shows that, compare with initial factors
and levels, loading of optimum factors and levels has value less than initial loading about
38.5%.

Table 5.4: Design of initial factors and optimum factors 54242.43N

Maximum
Order Factors and levels
loading
Design of initial 119256.35
A2 B3 C3 D3 E3
factors and levels N
Design of
optimum factors A2 B3 C1 D2 E1 73309.39N
and levels

54
 Figure 5.13: The finishing flange nut

5.2.3 Analysis of Volume

In cold forging, work-piece volume after product is formed completely very important. For
flange nut, this research used Deform 3D software to simulate forming process, but because of
Deform software characteristic so at every simulation process, work-piece volume would
decrease a little bit. Therefore work-piece volume needs to be considered, table 5.13 below
shows work-piece volume of every process.

Table 5.4: Work-piece volume before and after simulation

Work-piece volume Work-piece volume

Percent of loss
Process before simulation after simulation
(%)
(mm3) (mm3)
Process 1 1753.99 1752.1 0.1
Process 2 1752.1 1749.52 0.14
Process 3 1749.52 1747.94 0.09
Process 4 1747.94 1745.61 0.13

At table 5.3 above, volume of work-piece from first process to fourth process reduces not
considerably, about 0.09 to 0.14 %. So this study can ignore the effect of work-piece volume.

55
 Chapter 06
RESULTS AND DICUSSION

This research focused on flange nut cold forging processes. Lowest loading achieved
through the combination of FEM and Taguchi experiment. The following results and
discussion are described:

1. From analysis of simulation results above, this research indicates that optimal forming
load achieved through FEM combine with Taguchi experiment. Also, this study investigated
the affection of factors which effect flange nut forming process. From that, optimal factors
were found out and simultaneously the research also pointed out which factors have most
affection to flange nut forming process. In addition, the accuracy of product dimension almost
agreed with the design. The losing of work-piece volume is careful considered because it has
the effective to the precise of product as well as filling die.

2. At this research, analysis of stress also is careful examined because the stress has almost
effective to die and tool surface wear, the larger the stress is, the more effective of die and tool
wear will be. Simultaneously, it also would cause decreasing tool life. The stress in this
research has the largest value of 100Mpa.

3. In addition, there are some problems occurring in cold forging process as at piercing
stage, it appears some chips and flashes at inside hole surrounding as figure below. But these
issues would not be big problem which causing difficulty for tap operation at other research.

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 Figure 5.13: Diagram of chips and flashes after piercing

Chapter 07
CONCLUSIONS AND FUTURE WORK

7.1 Conclusions

The main object of this research is to optimize forming load in cold forging flange nut
forming process. The effects of geometric parameters were investigated on the draft angle and
punch depth. The research results indicated that there is an optimization of forming load in
flange nut forming process. The predicted results including stress distribution, the forging load
and the volume loss of work-piece in cold forging process were then carefully investigated.
The conclusions from this research are as follows:

1. Forming load obtained the optimization with the value of 73309.39N and with the
optimal factors and levels are: A2-B3-C1-D2-E1
2. Taguchi method was used to come up with the optimal shape of master die as well
as reduce number of experiments in order to decrease time and cost.
3. Draft angle and punch depth are the influential parameters affecting the flange nut
forming process.
4. Deform is based on the finite element method and unavoidably, it will encounter the
remeshing problem that result in loss volume of material.
5. From consideration of forming load, choice of production machine will be more
suitable for products, hence will reduce production cost.

7.2 Future Works

The stress distribution at second, third and fourth stage of the forming process are
relatively high, so future works need to research that reduce stress distribution by research
punch and die geometry for more suitable as well as forming stages.

57
 The material was used in the research need to change some other types such that
copper, aluminium or stainless steel with different dimensions.

The procedure of making flange nut can be able to change into less or much more
stages. Also, nuts geometry should be expanded to research with much more geometry such as:
heavy hexagonal nut, jam hexagonal nut or square nut, so on.

In the future, tap operation should be researched in order to produce completely flange
nut. From that product is able to apply to production practice.

58
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