The Relevance Of The Preform Design In Coining Processes Of Cupronickel Alloy

Abstract

Coining is a forging process in which a metallic disk, characterized by a low volume‐surface ratio, is deformed with the aim to impress 3D images on its three surfaces. Due to the large production volumes and, at the same time, to the high quality standards required to the final products in terms of final dimensions, tolerances and surface finishing, such closed‐die, cold forging process requires a careful evaluation and choice of the proper operative parameters. In particular, along with technological parameters as the die velocity, die stroke and lubrication, which, in turn, contribute to affect the pressure values on the die surfaces, and thus the press choice, geometrical parameters as the side ring inner diameter and, above all, the preform geometry, strongly affect the quality of the obtained parts. In this paper, a 3D FEM model for coining processes is proposed, that is Lagrangian implicit, rigid‐viscoplastic. The relationships between the obtained geometry and the starting preform shape is numerically investigated, allowing, through the analysis of the effective stresses, strain, and strain rate on the coin, as well as of the loads on the dies, to highlight the significance of the perform design in order to obtain a final product that satisfies the strict geometrical tolerances required. It is found that the best results on the final part are obtained with chamfered preform geometries, though larger values of force on the dies are observed.