Simulation and physical modeling of forging sequence of BJ type outer race

A constant velocity joint outer race is an important load-supporting part in cars. Its geometry is very complicated and its required precision is high. Traditional hot and cold forging methods have their own limitations to produce such a complex shaped part. Therefore, multistage forging may be advantageous to produce complex shaped parts. Actual problems in ironing sequence are prevention of ductile fracture and surface defects in final product and true formation of internal ball grooves of the workpiece. In this study Cockroft & Latham failure criterion was applied to final ironing sequence. Finally physical modeling is down using lead, In order to verifying simulation and damage modeling results the cross section profile of internal grooves is measured by a CMM machine and compared with simulation based profile.