Gear hot forging process robust design based on finite element method

Chen, Xuewen; Jung, Dong‐Won

doi:10.1007/s12206-008-0515-5

Cited by 11 publications

(6 citation statements)

References 11 publications

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“…Process parameter optimisation, similar to preform optimisation, is something which is often experience-based in practice. The studies presented in this paper describe scientific methods of optimisation which have the potential to ensure that the most of the process parameters are optimised on any occasion [25,58]. In terms of reducing forming load, the optimisation of parameters such as ram speed and temperature holds promise in promoting full filling of complex parts.…”

Section: Discussionmentioning

confidence: 99%

“…FE models in combination with Taguchi statistical loss function methods have been used to optimise such parameters. Chen [58] and Feng and Hua [25] have presented a parameter optimisation method for temperature, punch velocity and friction for the gear hot forging process based upon finite element simulation and Taguchi statistical analysis [59]. Feng and Hua [25] performed an optimisation, minimising forging force and stroke, for closed die forging of a helical gear of module 1.745 and 24 teeth using AISI-4120 steel.…”

Section: Process Parameter Optimisationmentioning

confidence: 99%

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A review of force reduction methods in precision forging axisymmetric shapes

Politis

Lin

et al. 2018

Int J Adv Manuf Technol

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This paper provides a review of the methods developed over the years for reducing working forces for the precision metal forming processes. Precision forging normally involves completely, or near completely closed cavity dies with no or minimal draft, making features on the extremities difficult to fill and requiring high loads. Means to minimise load, in order to enhance tool life, or reduce press capacity are crucial to the success of precision forging processes. The main concentration of this study is on design features which can be incorporated in tooling and/or workpiece in order to assist in minimisation of forging load while achieving complete die filling. The load reduction methods are presented using examples mainly of precision gear forging, which is representative of the precision forging of other axisymmetric components with complex peripheral shape. The methods reviewed are divided into the categories of (i) billet design, (ii) tool design and (iii) process design. Their effects on forging load reduction for precision forging, along with the authors' opinions as to the benefits, drawbacks and applicability of each, are presented.

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Section: Discussionmentioning

confidence: 99%

Section: Process Parameter Optimisationmentioning

confidence: 99%

A review of force reduction methods in precision forging axisymmetric shapes

Politis

Lin

et al. 2018

Int J Adv Manuf Technol

View full text Add to dashboard Cite

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“…Considering the constraint conditions, the gear optimization design can be converted to the optimal design problem with the constrained nonlinear mixed discrete variables [5]. So the following gear optimization design will use a new discrete optimization method which is based on the parametric design language of APDL [6]. Objective Function.…”

Section: Gear Discrete Optimization Designmentioning

confidence: 99%

Gear Stress Analysis and Discrete Optimization for Wheel-Legged Rover

Huang¹,

Wang

Fan

2012

AMR

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The wheel-legged rover with a double-half-revolution mechanism uses two tandem planetary gear trains to drive. Its virtual prototype model was built in COSMOS Motion software, and the mechanical data of each gears of the wheel-legged rover were obtained by dynamic simulation under the typical working conditions. On this basis, the finite element analysis model of the wheel-leg planetary gear was established and its stress analysis was done. The discrete optimization mathematical model was built with the optimization target of minimizing the rover’s wheel-leg planetary gear volume and the constraint condition of keeping the Mises stress applied on the dedendum under the admissible Mises stress. Based on ANSYS Parametric Design Language (APDL), the optimization design was done for the above gear based on discrete optimization method. The result shows that the optimized gear not only meets the strength requirement, but also its weight is 58% lower than the original, which will provide a new effective method for optimizing the wheel-leg structure of the rover.

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“…The gear hot forging process was previously conducted to reduce the forging force, and the optimal design parameters were established to minimize its variation. [1] For example, hot Forging of Automobile Steel Gear Blanks has explored such that the compromises between contraction of the under ll dimension as well as the ash surplus material) was illustrated. [2] On the studied materials for gear forming, magnesium alloy AZ31B spur bevel gear Hot forging process was conducted, and compared the experimental load-stroke curves with the calculated ones.…”

Section: Introductionmentioning

confidence: 99%

Numerical and Experimental Study on Tooth Filling via near Net Shape Extrusion-Forging Process of Multicore Cable Cutter

Hsu¹,

Chiu²,

Chen³

et al. 2021

Preprint

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The near net shape extrusion-forging and the impact of tooth filling computationally simulated and experimentally corroborated. The study plans to search for the finishing forging process's essential station and recognize the unique gear teeth forming in the closed die near net shape extrusion-forging connected with a multicore cable cutter. Due to make sure to realize the Preform types of gear teeth forming, The evaluation index of the height filling ratio (HFR) and the width filling ratio (WFR) methods are offered and simulated with a singular target on process parameters at the gear teeth making. All the objects are regularly investigated and precisely contrasted to experimental examination. The simulations' conclusions have explained the microscopic events after the experimental research. Via matching with experimental measurements, the accuracy of the numerical models has been confirmed. The offered modified geometries (Preform B and C) from the forming process have been eventually offered to achieve a resembling forming condition while lessening making charges.. The mean deviation of HFR was measured as 0.987% and 0.985% for Preform B and C, respectively. Moreover, the mean deviation of WFR was calculated as -0.693% and − 0.74% for Preform B and C, separately.

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Gear hot forging process robust design based on finite element method

Cited by 11 publications

References 11 publications

A review of force reduction methods in precision forging axisymmetric shapes

A review of force reduction methods in precision forging axisymmetric shapes

Gear Stress Analysis and Discrete Optimization for Wheel-Legged Rover

Numerical and Experimental Study on Tooth Filling via near Net Shape Extrusion-Forging Process of Multicore Cable Cutter

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