Precision forging of alternator poles by flow control method

Alternator poles have been conventionally produced by the multi–stage forging processes. As an alternative, several one–stage precision forging processes of alternator poles are put forward in this paper. The influence of different designs on metal flow and load requirements is examined through finite element simulation and experiments. It is shown that the design which has a moveable mandrel supported by a back force is useful to control the metal flow in the die cavity and to reduce the forging load. Well–shaped product can be forged successfully using a lower forging load by flow control method than that of conventional precision forging.