A Study on Two-Stage Cold Forging for a Drive Shaft with Internal Spline and Spur Gear Geometries

Ku, Tae-Wan

doi:10.3390/met8110953

Cited by 13 publications

(8 citation statements)

References 18 publications

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“…Based on the prior results related to the systematic approach to the process design for a drive shaft [17], in order to substantialize the drive shaft using the combined cold extrusion, parametric investigations focusing on the shoulder angle on each extrusion die were conducted and compliance evaluations on the dimensional specifications were carried out, then the appropriate combination of the process parameters was extracted in this study. Here, two shoulder angles of θ 1 on the extrusion die for the preform forging and θ 2 on that for the combined extrusion were selected as the main geometric variables.…”

Section: Introductionmentioning

confidence: 99%

A Combined Cold Extrusion for a Drive Shaft: A Parametric Study on Tool Geometry

2020

Materials

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Parametric investigations related to shoulder angle on tool geometry for a combined cold extrusion of a drive shaft, which consisted of spur gear and internal spline structures, were conducted through three-dimensional FE (finite element) simulations. The drive shaft was required to be about 92.00 mm for the face width of the top land on the spur gear part and roughly 22.70 mm for the groove depth of the internal spline section. AISI 1035 carbon steel material with a diameter of 50.00 mm and a length of 121.00 mm was spheroidized and annealed, then used as the initial billet material. A preform as an intermediate workpiece was adopted to avoid the excessive accumulation of plastic deformation during the combined cold extrusion. Accordingly, the cold forging process involves two extrusion operations such as a forward extrusion and a combined extrusion for the preform and the drive shaft. As the main geometric parameters influencing the dimensional quality and the deformed configuration of the final product, the two shoulder angles of θ1 and θ2 for the preform forging and the combined extrusion were both considered to be appropriate at 30°, 45°, and 60°, respectively. Using nine geometric parameter combinations, three-dimensional finite element simulations were performed, and these were used to evaluate the deformed features and the geometric compatibilities on the spur gear structure and the internal spline feature. Based on these comparative evaluations using the numerically simulated results, it is shown that the dimensional requirements of the target shape can be satisfied with the shoulder angle combination of (45°, 45°) for (θ1, θ2).

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Section: Introductionmentioning

confidence: 99%

A Combined Cold Extrusion for a Drive Shaft: A Parametric Study on Tool Geometry

2020

Materials

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“…Figure 1 a presents a sequential flow of the two-stage cold forging process used to produce the drive shaft, in which an internal spline with an irregular hexadecagonal cross-section and a sixteen-tooth spur gear were merged into a single metal member along a neutral axis. It can be seen that the round-type initial billet is shaped to the preform through the cold forward extrusion, and the preform is again deformed through the cold combined extrusion, which is defined as a forward–backward forging process, to obtain the cold forged drive shaft [ 25 , 26 , 27 ]. Given that the preform fabrication is the main object of this study, the subspecialized process flow is illustrated in Figure 1 b.…”

Section: Microstructural Characteristics and Mechanical Propertiesmentioning

confidence: 99%

“…In other words, considering that the two-stage cold forging process for producing the drive shaft is carried out continuously, it is also desirable to keep the FE models for the numerical simulations to maintain the same symmetric condition. Consequently, a one-sixteenth planar symmetric FE model for the cold forward extrusion was adopted for the forging punch and the extrusion die, as well as for the initial billet [ 25 , 26 , 27 , 28 ]. Figure 7 a depicts the three-dimensional FE models and the numerical simulation steps of the cold forward extrusion in order to visualize the preform.…”

Section: Numerical Simulations Of Cold Forward Extrusionmentioning

confidence: 99%

“…The preform dealt with in this study is also an intermediate workpiece fabricated through a cold forward extrusion process in order to produce a drive shaft as one of internal metal members that constitute an industrial hydraulic pump. Prior numerical and experimental studies related to the two-stage cold forging process for developing the drive shaft did not deal with the residual stress and the plastic deformation damage, including the hardness variation, because they were only focused on the stress distribution and the plastic deformation behavior, as well as the dimensional assessment and the forging load prediction [ 25 , 26 , 27 ]. However, when considering the operating environment of the drive shaft, it has to satisfy a basic series of critical requirements such as sufficient structural stiffness and mechanical strength against torque, substantial durability, and so forth.…”

Section: Introductionmentioning

confidence: 99%

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Numerical and Experimental Investigations on Residual Stress and Hardness within a Cold Forward Extruded Preform

2023

Materials

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Using a preform fabricated by a cold forward extrusion process, the present study numerically predicted and experimentally investigated its residual stress and microstructural characteristics, as well as its plastic deformation damage and hardness. Prior to realizing the preform, AISI 1035 cold-drawn medium carbon steel material with a diameter of 50.0 mm and a height of 121.0 mm is first spheroidized and annealed, after which phosphophyllite is used to coat its outer surface. To identify the influence of the spheroidizing and annealing on the mechanical properties and the microstructural phase, uniaxial compression tests and microscopic observations are carried out. After assuming the deformation behavior of the workpiece during the cold forward extrusion with a plastic material model and with an elasto-plastic material model, separately, three-dimensional finite element simulations are adopted to visualize the residual stress and the plastic deformation damage. The preform produced by cold forward extrusion is fully scanned by using an optical 3D scanner, the Vickers micro-hardness is measured, and the residual stress through EBSD (electron backscatter diffraction) analysis is observed. Briefly, the results show that the ferrite and pearlite within the raw workpiece is well spheroidized by the heat treatment, and that there is a decrease in the KAM (kernel average misorientation) value of about 40%. In terms of the preform obtained by the cold forward extrusion, the dimensional requirement is more suitably met with the predicted layout when adopting the elasto-plastic material model than that of the plastic material one, and the numerically predicted residual stress agrees with the Vickers micro-hardness distribution. It can be verified that the dislocation density (or the internally stored strain energy) based on the IQ map and the IPF map is substantially increased around the extrusion region, and that the KAM value is increased by roughly 516% as the whole average of the observed values.

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“…In a study by Deng et al, [5], a sound 3D rigid-plastic FE model of cold rotary forging of a 20CrMnTi alloy spur bevel gear has established utilizing the DEFORM-3D code and showed that it could be an effective tool in forging analyses. Ku [6] proposed a two stage cold forging for drive shaft with a forward extrusion for preform. The results indicated that the method could be well used to the production f drive shaft.…”

Section: Introductionmentioning

confidence: 99%

Development of Preform for Simulation of Cold Forging Process of A V8 Engine Camshaft Free from Flash & Under-Filling

et al. 2019

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Finite Element Method based techniques apply to a wide spectrum of engineering applications including manufacturing. The flexibility to achieve optimized results by simulations adds another dimension to process-development. The efficiency due to simulation is enhanced many folds for developing desired components by reducing the cost as well as time. This paper investigates cold forging process to be adopted to produce camshafts with a target to minimize flash as well as under filling. These two factors being major problems encountered when cold forging is to be adopted for complex shaped products. The current work is primarily concerned with the development of an optimized preform design for a V8 engine camshaft. The work involved the Solid modeling of the camshaft on AutoCAD and further analyzing the developed model through finite element analysis using Deform 3D. The analysis involved understanding of metal flow, volumetric analysis and die stresses in the forging process. The materials considered for the work-piece and the dies are AISI 8620 and AISI-H-26 respectively. The sample camshaft was taken from a standard Dodge Challenger V8 engine. 10 different cases are analyzed to find out the best possible scenario. It is fund that the stress level for the developed model was very much within the design limit of the material.

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A Study on Two-Stage Cold Forging for a Drive Shaft with Internal Spline and Spur Gear Geometries

Cited by 13 publications

References 18 publications

A Combined Cold Extrusion for a Drive Shaft: A Parametric Study on Tool Geometry

A Combined Cold Extrusion for a Drive Shaft: A Parametric Study on Tool Geometry

Numerical and Experimental Investigations on Residual Stress and Hardness within a Cold Forward Extruded Preform

Development of Preform for Simulation of Cold Forging Process of A V8 Engine Camshaft Free from Flash & Under-Filling

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