Application of CAE for hot-forging of automotive components

Since the late 1980s, the commercial based forging analysis software has come into the market and brought some benefits for optimizing forging processes. Nissan Motor Co. has applied CAE (computer-aided engineering) mainly to hot-forging processes. This paper describes three examples of simulations which were applied to our hot-forging plant floor. The first example is a model experiment using Plasticine and FE (finite-element) simulation with analysis of variance using the orthogonal array to reduce the amount of input material for crankshaft forging. The second example is of a die stress analysis for extending the lifetime of a die for forging side flanges. The final example is an application of CAE for the development of a forging expert system to prevent defects in hot-forged components.