Date of Publication :31st July 2024

Abstract:The cold heading process is a multistage process which is performed without an external heat source. The occurrence of internal ductile failure in cold-headed products is caused by the adiabatic shear band phenomenon. This type of failure presents a significant obstacle in the fast-expanding cold heading industry. The existence of these types of ductile failure in cold-headed products may lead to catastrophic fracture under tensile loads despite the ductile nature of the material. The current work presents a comprehensive experimental and finite element methodology to implement the stress instability workability criterion in assessing and improving multistage cold heading procedures. The new methodology showed that it is an efficient tool to predict the damage levels and failure initiation locations within cold-headed products. Moreover, this methodology is successful in optimizing the die designs to reduce damage levels.

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