FE simulation of multi-stage cold forging process for metal shell of spark plug manufacturing

Design of the multi-stage cold forming processes is built using the 3D geometry model by the Solid Works software. The geometry models of the six stages of the Metal Shell of Spark Plug manufacturing are imported to Simufact. Forming the software for settings the FE simulation. To get the flow stress, frictional factor, cylinder compression test and ring compression test of AISI 1010 steel are performed. The product parts dimensions, forging loads, effective stress, contact pressure and velocity field, are determined and discussed. Finally, the actual product parts dimensions and forging loads at each stage are compared between the FE simulation results and verified the analysis acceptance. The deviation of the MSSP geometry dimensions is about (4%) and forging loads are within the readings range of the actual machine. The results will help the designers to realize the forging loads and forming conditions at any stage. As a result, the optimal design and planned production can be acquired.