此外，數值模擬和實驗驗證過程中其詳細的模具設計和尺寸的變化，在鍛品及沖頭的整體結構完整性上，對於鍛造過程，其穩定性上是相當重要的。此外，鍛造上所產生之廢料比，其所鍛造之方式產生之內外環上，可減少之廢料佔整體棒材體積而言約9%左右。再者，在其多道次溫鍛過程中其模具鍛造產量可達每小時10,000件內外環，而在整體鍛造上其鍛品具有完整之結構穩定性。 ;In this study, a multi-stage warm forging process for making bearing rings is numerically and experimentally investigated. The aim of the study is to determine the crucial station of the finishing forging process such that the tool wear is prolonged and tool fracture should be minimized. In addition, in order to ensure the appropriateness of the suggested modification, a 3-dimensional finite element simulation on each sequence is performed, and carefully compared with experimental investigations. Numerical simulations results indicate that the redesigned upper punch geometry, radius(R2) of the finishing forging process, demonstrates drastically different deformation rate (the effective strain/effective stress distribution) and material flow pattern, as compared with chamfer (C2) counterpart. Accuracy of the numerical models has been verified by comparing with experimental measurements . In addition, the numerically and experimentally validated process includes the detailed tooling design and dimension variation, which is of great importance in maintaining the overall structural integrity of the forging die/punch and thus, the stability of the whole process. Concerning on the waste ratio comparison, the method used steel rods are as raw material and the IR/OR rings form is given by hot/warm forging and sequential cold rolling processes and the waste ratio decreases to ~9%. Finally, it is shown that the multi-stage warm forging process in this study could be successfully applied to the high-quantity production (10,000 pieces/hr) of the IR/OR of the deep groove ball bearing with the stability and structural integrality of the whole process.
