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Manufacturing of a Wheel Nut With Outer Hexagon
Dvořák, Ondřej ; Forejt, Milan (referee) ; Řiháček, Jan (advisor)
The thesis deals with the design of a production technology for a wheel nut with an external hexagon, a tapered seating surface, and a shank. The production series is set at 200,000 pieces per year. The raw material is a coil of wire with a circular cross-section and a diameter of 20 mm made of steel 11 320. After evaluating the specified requirements and conducting a literature review, the production technology of cold forming is selected, specifically the combination of extrusion and upsetting. Three basic production processes are designed, which are subsequently optimized, and their manufacturability is verified using the simulation program Simufact Forming 1.6. For the most suitable production variant, the flow stress, deformation resistance, and forming forces are calculated for each operation. By comparing with the simulation results, the total force required to produce the given nut is determined, which is crucial for selecting a suitable machine. The forming machine used is a CBF 204L with a nominal force of 3,500 kN, for which a three-operation tool is designed. During the tool design, the internal radial pressure acting on the die is also verified. The results indicate that it is necessary to use encapsulation using a single clamp for the second operation. The tool is constructed to be compatible with the parts of the chosen machine according to the provided layout and available machine parameters.
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