Numerical approach to forging process of a gear with inner cam profile using FEM

Kang, Gyung-Ju; Song, Woo‐Jin; Kim, Jeong; Kang, Beom-Soo; Park, Hoon-Jae

doi:10.1016/j.jmatprotec.2005.02.137

Cited by 12 publications

(6 citation statements)

References 10 publications

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“…With the fast development of computer hard and soft wares, finite element method (FEM) and computer graphics, the computer aided engineering technology based on numerical simulation is used widely in metal plastic forming field. The simulation of metal forming processes can be realized on the computer [4][5][6] . The precision forging processes of gears can be studied with three-dimensional FEM.…”

Section: Introductionmentioning

confidence: 99%

Process Design for Cold Precision Forging of Bevel Gear

Zhang

Cui

Wang

2010

2010 International Conference on Digital Manufacturing &Amp; Automation

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Precision forging is defined as a near net-shape forging operation which generates high quality parts concerning surface quality and dimensional accuracy. In particular gears offer a wide application field for the precision forging technology. Advantages like shortened production cycles achieved by eliminating machining operations and the saving of raw material contribute to the ongoing cost-saving trend in the industry. This article describes the adopted methods and the precision forging process of the bevel gear. 3D FEM model of the precision forging process of bevel gear was established. The forming laws, material plastic behavior, changed geometries and the qualities of the gears are explored by finite element simulation. Completely filled gear teeth were obtained using a lower forging load by the designed process which is the effective forging process for manufacturing of bevel gear. The design process for bevel gear has to be purpose-built to consider the distinctions of this precision forging technique.

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Section: Introductionmentioning

confidence: 99%

Process Design for Cold Precision Forging of Bevel Gear

Zhang

Cui

Wang

2010

2010 International Conference on Digital Manufacturing &Amp; Automation

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“…Also, to investigate the effect of coating treatment on the friction characteristic, ring compression tests were executed. As shown in Table 1, mechanical properties such as yield strength, tensile strength, elongation and reduction of area, and friction factors calculated from FE analysis and experiments can be found in a previous study [13]. From the study, the stress-strain relation of SAE8620H is s ¼ 857:14« 0:2028 .…”

Section: Mechanical Properties and Friction Coefficientmentioning

confidence: 85%

“…in which f f is the reduction of area. By substituting the reduction of area 0.631 [13] into equation ( 3), a fracture strain of 0.997 can be obtained. In order to obtain a damage value C, the Cockroft-Latham ductile fracture equation, which is usually used in the cold forging process, is applied [14,15].…”

Section: Tensile Fracturementioning

confidence: 99%

Numerical and experimental evaluation for elastic deformation of a cold forging tool and workpiece for a sleeve cam of an automobile start motor

Kang¹,

Kim²,

Kang³

2008

Proceedings of the Institution of Mechanical Engineers, Part B:

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The dimension of the final stage of cold forging a product is different from that of the die. The difference is influenced by various effects such as elastic deformation of the die and elastic recovery of the billet. In this study, in order to investigate the trend of elastic expansion of the die and elastic recovery of the billet, which is important to develop dimensional accuracy of the die, a finite element analysis was carried out using a commercial FEM code, DEFORM-3DTM. The die was designed according to the analysis results. Real elastic deformation of the die was obtained from both the rigid die model analysis and compensation by shrink fitting. Further, the forging process was evaluated by ductile fracture criteria. Finally, gear manufacturing based on the designed die is carried out. By measuring the results of the gear it was shown that the manufactured gear satisfies the JIS 6 class. The cold forging technology developed in this study to manufacture a gear part with a complicated shape is expected to be used effectively for production of other precision parts.

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“…Several works were also concerned to dimensional accuracy related with elastic deformation of tool and component. [6][7][8][9][10][11] The majority of these studies [1][2][3][4][5][6][7][8][9][10][11] concerned mainly on the elastic behavior characteristics of tool and the component in cold upsetting and cold extrusion instead of cold ironing process, and less research is engaged into spur gear parts precision forming. There is almost no research reporting about the elastic deformation characteristics for spur gear cold ironing process, especially focused on elastic deformation trend of involute curve profile.…”

Section: Introductionmentioning

confidence: 99%

Study of elastic deformation on dimensional accuracy in ironing process of spur gear

Gao

Zhou

et al. 2016

Proceedings of the Institution of Mechanical Engineers, Part B:

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The cold ironing process of a warm forged spur gear was applied to investigate the elastic distortions arising by the behavior of die elastic expansion and gear elastic recovery in this article. An elasto-plastic finite element simulation was performed to analyze the elastic behavior characteristics of gear and die. The effects of interference between gear and die on the elastic distortions were investigated through finite element simulation and experiment, respectively. The change of geometrical profile and dimension of the gear tooth were measured; the estimated dimension of ironed gear by finite element simulation was fitted to the experimental results well within the range of 5% relative error. Furthermore, in order to improve the dimensional accuracy of final forged gear, this study proposed a die cavity compensation method to compensate cavity of the ironing die, which was obtained by shrink fitting a outer ring into the initial ironing die. The optimum radial interference between stress ring and initial shrink-fitted die was calculated based on the Lame formula and thick wall cylinder theory. Finally, an experiment according to the proposed die cavity compensation method was carried out to examine the validity of analytical results and demonstrated that predicted dimensions could be achieved and dimensional accuracy greatly improved. It was shown that the manufacture gear satisfies the IOS6 class by measuring the iron-forged gear.

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Numerical approach to forging process of a gear with inner cam profile using FEM

Cited by 12 publications

References 10 publications

Process Design for Cold Precision Forging of Bevel Gear

Process Design for Cold Precision Forging of Bevel Gear

Numerical and experimental evaluation for elastic deformation of a cold forging tool and workpiece for a sleeve cam of an automobile start motor

Study of elastic deformation on dimensional accuracy in ironing process of spur gear

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