Multi-stage cold forging and experimental investigation for the outer race of constant velocity joints

Ku, Tae-Wan; Kim, Lee-Ho; Kang, Beom-Soo

doi:10.1016/j.matdes.2013.01.030

Cited by 28 publications

(15 citation statements)

References 20 publications

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“…Because the drive shaft shown in Figure 1a has a whole length of more than about 169.5 mm and includes the different cross-sectional configurations along the longitudinal direction of the shaft, if a single cold forging operation is applied to obtain the drive shaft from the initial round billet, it is hard to realize the final product without crucial defects, such as material damage and surface cracks caused by excessive plastic deformation. To avoid these defects, the preform or the intermediate workpiece is commonly applied in many cases of manufacturing the mechanical-structural metal components with a high degree of difficulty in the target geometry [8,16,17]. By doing so, the excessive plastic deformation and critical defects can be prevented in advance.…”

Section: Process Design For Two-stage Cold Forgingmentioning

confidence: 99%

“…The two-stage cold forging process in this study was defined as a quasi-static process, so any influence of the strain rate was disregarded. As for the other consideration, the friction coefficient between the tool components and the workpieces was assumed to be 0.098 as the shear friction behavior, during the two-stage cold forging operations were performed, because the surface of the spheroidized and annealed billet material was treated to reduce the friction effect by a phosphophyllite coating (Zn2Fe(PO4)2) [8,12,13]. Figure 5a shows the forging punch and the dies to simulate the forward extrusion process, and Figure 5b displays the backward extrusion punch and the forward extrusion-gearing die to realize the drive shaft by the forward-backward forging.…”

Section: Three-dimensional Finite Element Modelsmentioning

confidence: 99%

“…For example, a forward extrusion for shaping the spur gear and a backward operation for configuring the internal spline are both needed. Most recent issues related to metal forging technology are associated with pursuing the goals of process simplification and improving the efficiency to increase the productivity and enhancei the yield percentage of material, as well as reducing the manufacturing cost [7,8]. A variety of research activities to address these issues caused by the complexity of the target geometry have been ongoing in various forging fields, and several combined forging processes have been introduced and reported [9,10].…”

Section: Introductionmentioning

confidence: 99%

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

2018

Metals

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A two-stage cold forging process was proposed to manufacture a drive shaft with an internal spline and spur gear geometries, and this process was mainly composed of a forward extrusion for preform and a forward-backward extrusion for the drive shaft. In the process design, the preform was designed using a volume apportioning scheme from the required target shape, thereafter, the initial round billet was outlined. AISI 1035 carbon steel was selected as the raw material, and a spheroidizing heat treatment was adopted. Using the raw and spheroidizing annealed workpieces, uni-axial tensile and compression tests were carried out to evaluate the effect of the heat treatment and to measure the mechanical properties. Finite element simulations were sequentially performed to assure the suitability of the proposed process design. Considering the results from the process design and the numerical simulations, the related tool components were prepared and applied to a series of experimental investigations. The preform and the drive shaft fabricated by the two-stage cold forging experiments were compared with the required target and the numerically predicted configurations. The results indicated that the two-stage cold forging process proposed in this study could be well applied to the production of the drive shaft with an internal spline and spur gear structures.

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Section: Process Design For Two-stage Cold Forgingmentioning

confidence: 99%

Section: Three-dimensional Finite Element Modelsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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

2018

Metals

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“…al. [9] proposed multi-stage cold forging and experimental investigation for the outer race of constant velocity joints. Joun et.al [10] presented an application-oriented finite element approach to forging die structural analysis.…”

Section: Related Work and Problemsmentioning

confidence: 99%

Collaborative Knowledge for Analysis Material Flow of a Complex Long Stud Using Multiple Stoke Cold Heading

Butdee

Khanawapee

2015

Advances in Production Management Systems: Innovative Production Management Towards Sustainable Growth

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Productivity Improvement is one of the most important strategies for every enterprise. Head cold forging is a widely common production process which can achieve economical processes and less energy consumption. Die is the major key of the forging process but how to perform an effective design, needs several years of experiences or using engineering tools for assistance. This paper proposes the collaborative die design and analysis by combining engineering methods and industrial experts to correct problems and to validate a new and complex design. DEFORM is used to investigate suitable parameters by guidance from the expert. One of the classical problem in the head cold forging is to make a small long complex stud. It is found from simulation that a five step of punch with suitable taper angle is the most effectiveness.

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“…Pang et al [ 8 ] used multi-stage cold forging for manufacturing hollow power-transmission long shafts. Ku et al [ 9 ] successfully replaced traditional multi-stage warm forging with multi-stage cold forging to produce constant-velocity joints. The products manufactured revealed excellent mechanical properties.…”

Section: Introductionmentioning

confidence: 99%

Multi-Stage Cold Forging Process for Manufacturing a High-Strength One-Body Input Shaft

Jeong

Lee

et al. 2021

Materials

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A multi-stage cold forging process was developed and complemented with finite element analysis (FEA) to manufacture a high-strength one-body input shaft with a long length body and no separate parts. FEA showed that the one-body input shaft was manufactured without any defects or fractures. Experiments, such as tensile, hardness, torsion, and fatigue tests, and microstructural characterization, were performed to compare the properties of the input shaft produced by the proposed method with those produced using the machining process. The ultimate tensile strength showed a 50% increase and the torque showed a 100 Nm increase, confirming that the input shaft manufactured using the proposed process is superior to that processed using the machining process. Thus, this study provides a proof-of-concept for the design and development of a multi-stage cold forging process to manufacture a one-body input shaft with improved mechanical properties and material recovery rate.

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Multi-stage cold forging and experimental investigation for the outer race of constant velocity joints

Cited by 28 publications

References 20 publications

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

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

Collaborative Knowledge for Analysis Material Flow of a Complex Long Stud Using Multiple Stoke Cold Heading

Multi-Stage Cold Forging Process for Manufacturing a High-Strength One-Body Input Shaft

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