Simulation of clutch-hub forging process using CAMPform

An inner gear component, clutch-hub, was chosen as the object for a numerical study investigating the usefulness and effectiveness of employing numerical simulations in the design process of metal forming parts. A computer-aided design simulation tool CAMPform was employed in this study. Simulations for S10C steel using various die and workpiece geometries were carried out, and completeness of filling and load requirements were compared to determine the forming condition most suitable for production of the clutch-hub. The effect of shear friction factor on the forming process was examined using the most suitable die and workpiece geometries. Also, study on aluminum alloys Al1100-O, Al2024-T3, Al6061-T4 and Al7075-T4 with respect to their defect factors of work hypothesis, (C-1) and Cockcroft and Latham (C-2) were made in this paper. It was found that only Al6061-T4 could be considered as a substitute material of steel for cold forging of the clutch-hub. (C) 2002 Elsevier Science B.V. All rights reserved.