Establishment of a Predictive Model for Cold Forging Force in Fastener Manufacturing Using Numerical Analysis

Precise metal parts are manufactured using cold forged screw forming, but this method has drawbacks such as material damage and the possibility of imprecise parts. To ensure the accuracy and quality of parts, it is crucial to analyze and predict the forging force in this process. There are various methods to predict the forging force including laboratory testing, numerical simulation techniques, and simulation techniques. To provide forging information that cannot be measured by forging-forming machines, we simulated the nut-forming process based on actual manufacturing conditions using SolidWorks (v2020) with DEFORM-3D (v6.1). The results showed that the performance of the prediction of forging force specifications by the currently available nut-forming machines was improved by 8−20%. As the product becomes larger, the difference in forging force also increases proportionally. This research result, combined with appropriate experimental analysis, can be used as parameter controls for manufacturers in the future implementation of smart manufacturing.