Scientific Research and Essays

  • Abbreviation: Sci. Res. Essays
  • Language: English
  • ISSN: 1992-2248
  • DOI: 10.5897/SRE
  • Start Year: 2006
  • Published Articles: 2751

Full Length Research Paper

Prediction of geometric defects in the cold embossing of AA6061 aluminum alloy by finite element analysis

  A. B. Abdullah1,2*, S. M. Sapuan2, Z. Samad1, H. M. T. Khaleed1 and N. A. Aziz2        
  1School of Mechanical Engineering, Universiti Sains Malaysia, Engineering Campus, 14300 Nibong Tebal, Penang, Malaysia. 2Department of Mechanical and Manufacturing Engineering, University Putra Malaysia 43400 Serdang, Selangor, Malaysia.
Email: [email protected]

  •  Accepted: 05 April 2012
  •  Published: 30 April 2012


The precision of near-net shape manufacturing processes such as cold forging is crucial. Defects may affect the assembly accuracy and thus cause decreased system performance. Therefore, these defects must be predicted and minimized as early as possible before proceeding to the manufacturing stage. This paper aims to study the geometric defects in the cold embossing pin head. The defects can be measured based on the incomplete filling and geometries of bulging. The effect of the distance to edge (DTE) on the defect pattern is predicted based on the material flow pattern. The DTE is found to have a significant effect on defect formation. The size of bulging is reduced and the filling ability is improved with increased DTE. 

Key words: Cold embossing, material flow pattern, geometrical defect, distance to edge.