Multi-station Forming Process Analysis and Die Design of a Multi-step Double-pass Connecting Joint

FANG Jie; TONG Zeqi; HU Kaiming; WU Jianjun; CAI Yafang

doi:10.3969/j.issn.1674-6457.2026.04.020

PDF(7670 KB)

Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (4) : 196-205. DOI: 10.3969/j.issn.1674-6457.2026.04.020

Advanced Manufacturing Technology and Equipment

Multi-station Forming Process Analysis and Die Design of a Multi-step Double-pass Connecting Joint

FANG Jie¹, TONG Zeqi^2,*, HU Kaiming¹, WU Jianjun¹, CAI Yafang¹

Author information +

History +

Abstract

The work aims to select a multi-step double-pass connecting joint as the research object to address the issues of incomplete forming, insufficient punching, and low dimensional accuracy in the hot forging process. Numerical simulation experiments were conducted with the finite element method. The multi-station hot forging process was simulated with Deform-3D software to investigate the metal flow behavior and temperature evolution of the forging. The analysis focused on the filling integrity of the forging, the peak variation trend of forming load, the distribution uniformity of equivalent stress and strain, as well as the cross-sectional temperature difference of the forging. In addition, die design and trial production were carried out for the multi-station scheme. The simulation results showed that, in the multi-station forming process, the surface node distribution of the forging was uniform, metal flow was normal, and no folding or other defects occurred, with no underfilling inside the die. The forming load increased steadily without abrupt changes in stress or strain, and the temperature difference remained within a reasonable range. The final forging met the specified external dimensional requirements. In the trial production, the forgings exhibited good formability, complete die filling, clear punching, and dimensional accuracy within tolerance. For the multi-step double-pass connecting joint, the multi-station forming process effectively avoids forging defects. The feasibility and reliability of applying the multi-station hot forging process to the multi-step double-pass connecting joint are verified through both simulation and experimental results, providing a reference for the precision forging of similar complex structural components.

Key words

multi-step double-pass connecting joint / precision forging and forming process / multi-station design / plastic forming simulation / die design

Cite this article

EndNote

Ris (Procite)

Bibtex

Download Citations

FANG Jie, TONG Zeqi, HU Kaiming, WU Jianjun, CAI Yafang. Multi-station Forming Process Analysis and Die Design of a Multi-step Double-pass Connecting Joint[J]. Journal of Netshape Forming Engineering. 2026, 18(4): 196-205 https://doi.org/10.3969/j.issn.1674-6457.2026.04.020

References

[1] SANDERS D G, RAMULU M.Examination of Superplastic Forming Combined with Diffusion Bonding for Titanium: Perspective from Experience[J]. Journal of Materials Engineering and Performance, 2004, 13(6): 744-752.
[2] PENG J, LI X Y.A Numerical Simulation of the Seismic Performance and Residual Stress of Welded Joints in Building Steel Structures Based on the Finite Element Method[J]. Processes, 2024, 12(2): 263.
[3] DU X J, CHEN Z Z, SONG J L, et al.Multi-Objective Optimization of Vehicle Body B-Pillar Lower Joints Based on Crashworthiness Analysis[J]. Advances in Mechanical Engineering, 2024, 16(7): 16878132241263506.
[4] JUANGTAK R Y U, KIM P S, JOO L H. A Study on the Development of Quality Inspection System for Connector Components Used in Automotive Wiring[J]. Journal of the Korea Society Industrial Information System, 2021, 26(6): 11-6.
[5] PATRICK C C.High-Temperature Ceramic Silver Paste Connectors: Fabrication and Performance Analysis[M]. Youngstown: Youngstown State University, 2024.
[6] ASWATHY M S, SARKAR S.Effect of Stochastic Parametric Noise on Vortex Induced Vibrations[J]. International Journal of Mechanical Sciences, 2019, 153: 103-118.
[7] HE X F, DONG Y H, LI Y H, et al.Fatigue Crack Growth in Diffusion-Bonded Ti-6Al-4V Laminate with Unbonded Zones[J]. International Journal of Fatigue, 2018, 106: 1-10.
[8] 李蕊, 游晓燕. 基于有限元分析的螺套冷锻工艺改进[J]. 锻压技术, 2024, 49(8): 21-28.
LI R, YOU X Y.Improvement of Cold Forging Process for Screw Sleeve Based on Finite Element Analysis[J]. Forging & Stamping Technology, 2024, 49(8): 21-28.
[9] 张志, 武波涛, 张国新, 等. 基于Deform-3D的汽车发动机十二角轴套多工位冷镦技术[J]. 锻压技术, 2024, 49(6): 52-60.
ZHANG Z, WU B T, ZHANG G X, et al.Multi-Station Cold Heading Technology for Automotive Engine Twelve Corner Shaft Bushing Based on Deform-3D[J]. Forging & Stamping Technology, 2024, 49(6): 52-60.
[10] PARK D H, HAN S C.Development of Spur Gear Parts for Automotive Actuators Using Precision Cold Forging Technology[J]. Transactions of Materials Processing, 2023, 32(6): 335-43.
[11] HAWRYLUK M, ZWIERZCHOWSKI M, RYCHLIK M, et al.Analysis of the Industrial Process of Producing a Lever-Type Forging Used in Motorcycles[J]. Archives of Metallurgy and Materials, 2019: 1421-1432.
[12] 陈鸿玉, 刘吉飞, 程明达, 等. 海上石油平台常压软管和快速接头的类型及选用[J]. 中国石油和化工标准与质量, 2025, 45(1): 34-36.
CHEN H Y, LIU J F, CHENG M D, et al.Types and Selection of Atmospheric Hoses and Quick Connectors for Offshore Oil Platforms[J]. China Petroleum and Chemical Standard and Quality, 2025, 45(1): 34-36.
[13] GUPTA A K, ANIRUDH V K, SINGH S K.Constitutive Models to Predict Flow Stress in Austenitic Stainless Steel 316 at Elevated Temperatures[J]. Materials & Design, 2013, 43: 410-418.
[14] PRASAD K S, GUPTA A K, SINGH Y, et al.A Modified Mechanical Threshold Stress Constitutive Model for Austenitic Stainless Steels[J]. Journal of Materials Engineering and Performance, 2016, 25(12): 5411-5423.
[15] 高畅, 刘发美, 金俊松, 等. 带环形凸台薄盘形件旋压成形规律研究[J]. 精密成形工程, 2024, 16(3): 145-151.
GAO C, LIU F M, JIN J S, et al.Spinning Forming Process for Thin Disc Parts with Annular Boss[J]. Journal of Netshape Forming Engineering, 2024, 16(3): 145-151.
[16] 陈保山, 逯云杰. 基于Deform-3D的齿轮坯精锻工艺分析与试验验证[J]. 锻压技术, 2023, 48(12): 18-24.
CHEN B S, LU Y J.Analysis and Experimental Verification of Gear Billet Precision Forging Process Based on Deform-3D[J]. Forging & Stamping Technology, 2023, 48(12): 18-24.
[17] 田亚丁, 朱绘丽. 基于有限元分析的汽车法兰盘连接件精密锻造工艺[J]. 锻压技术, 2023, 48(12): 9-17.
TIAN Y D, ZHU H L.Precision Forging Process on Automotive Flange Connection Part Based on Finite Element Analysis[J]. Forging & Stamping Technology, 2023, 48(12): 9-17.
[18] 杨忠, 王彦凤. 汽车用薄壁管件预制坯设计及成形工艺模拟[J]. 锻压技术, 2023, 48(2): 102-110.
YANG Z, WANG Y F.Preformed Billet Design and Forming Process Simulation for Automobile Thin-Walled Pipe[J]. Forging & Stamping Technology, 2023, 48(2): 102-110.
[19] 张治民, 贾晶晶, 董蓓蓓, 等. 镁合金尾翼类构件径向同步加载工艺研究[J]. 精密成形工程, 2024, 16(7): 57-65.
ZHANG Z M, JIA J J, DONG B B, et al.Radial Synchronous Loading Forming of Magnesium Alloy Empennage-Shape Components[J]. Journal of Netshape Forming Engineering, 2024, 16(7): 57-65.
[20] 田亚丁, 刘德波. 基于数值模拟的变速箱轴套精锻工艺评估及试验研究[J]. 精密成形工程, 2024, 16(1): 192-200.
TIAN Y D, LIU D B.Evaluation and Experimental Research on Precision Forging Process of Gearbox Shaft Sleeve Based on Numerical Simulation[J]. Journal of Netshape Forming Engineering, 2024, 16(1): 192-200.
[21] 李帆, 邢亚哲. 基于Deform-3D的汽车活塞轴套锻造过程分析及工艺改进[J]. 锻压技术, 2024, 49(8): 13-20.
LI F, XING Y Z.Analysis on Forging Process and Process Improvement for Automotive Piston Shaft Sleeve Based on Deform-3D[J]. Forging & Stamping Technology, 2024, 49(8): 13-20.
[22] CEVIZ M, CETINTAV I.Finite Element Simulation and Experimental Study on Defects in CuZn₄₀Pb₂ Brass Alloy Water Valve Covers during Hot Forging[J]. Proceedings of the Estonian Academy of Sciences, 2025, 74(1): 82-89.
[23] SUN W H, YANG C P.Simulation of Cross Wedge Rolling and Hot Extrusion-Combined Forming Process for Axle Sleeve[J]. Metals, 2023, 13(6): 1017.
[24] LI Z H, LU Y B.Optimization of Precision Forging Process for Large Flange Cylinder Parts[J]. International Journal of Precision Engineering and Manufacturing, 2025, 26(5): 1117-1129.
[25] 王耀, 顾小燕. 三通阀体多向模锻工艺研究及有限元分析[J]. 锻压技术, 2022, 47(3): 28-33.
WANG Y, GU X Y.Study on Multi-Directional Die Forging Technology for Tee Valve Body and Finite Element Analysis[J]. Forging & Stamping Technology, 2022, 47(3): 28-33.
[26] 吴小亮, 蔡丹云, 周裕鹏, 等. 凸焊螺栓多工位冷镦成形工艺及模具设计[J]. 锻压技术, 2024, 49(6): 81-87.
WU X L, CAI D Y, ZHOU Y P, et al.Multi-Station Cold Heading Process and Mold Design for Projection Welding Bolt[J]. Forging & Stamping Technology, 2024, 49(6): 81-87.
[27] 丛兵兵, 孔明, 张弘斌, 等. 马车螺栓冷镦成形有限元模拟及模具设计[J]. 塑性工程学报, 2022, 29(2): 76-81.
CONG B B, KONG M, ZHANG H B, et al.Finite Element Simulation and Die Design of Cold Heading Forming for Carriage Bolt[J]. Journal of Plasticity Engineering, 2022, 29(2): 76-81.