Precision forging processes for high-duty automotive components

Behrens, Bernd‐Arno; Doege, E.; Reinsch, Steffen; Telkamp, Kathrin; Daehndel, H.; Specker, A.

doi:10.1016/j.jmatprotec.2006.03.132

Cited by 62 publications

(35 citation statements)

References 6 publications

(7 reference statements)

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“…The final outer radius of the forged part is r. Thus, the difference between R and r is the dimensional difference in radius between the die and the forged part, U, as shown in Eq. (1).…”

Section: Tool Design and Fabricationmentioning

confidence: 99%

See 1 more Smart Citation

An investigation of involute and lead deflection in hot precision forging of gears

Zuo

Wang

Zhi

et al. 2016

Int J Adv Manuf Technol

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A theoretical model is presented in the paper for predicting involute profile deflection in hot precision forging of gears. This model is a function of a number of material and processing parameters, including the thermal expansion of the die, thermal contraction of workpiece, elastic expansion of the die during forging, and workpiece recovery after ejection. To improve the accuracy of the hot forged gear tooth, an equation set to define modified involute that is used to design the die tooth has been proposed based on the model. The distribution of deflection along the involute was also predicted using the commercial FE code, PRO-E. The deflection characteristic of the toothed die through the tooth width was analyzed by combining the theoretical method and FEM to investigate the nonuniform deflection. The dimension of the forged gears was measured using a gear measurement machine WGT3000. A close agreement between predicted and measured tooth involute profiles was obtained, which validated the involute deflection prediction model. The measured lead error also verified the model for deflection non-uniformity through the tooth width. The results can provide a guide for die tooth designs to improve the dimensional accuracy of hot forged gear teeth.

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“…The final outer radius of the forged part is r. Thus, the difference between R and r is the dimensional difference in radius between the die and the forged part, U, as shown in Eq. (1).…”

Section: Tool Design and Fabricationmentioning

confidence: 99%

“…The market demand for gears has been increased significantly in recent years [1]. High accuracy, productivity, and the capability in gear manufacturing have been receiving significant attentions [2].…”

Section: Introductionmentioning

confidence: 99%

An investigation of involute and lead deflection in hot precision forging of gears

Zuo

Wang

Zhi

et al. 2016

Int J Adv Manuf Technol

View full text Add to dashboard Cite

show abstract

“…This reduces mechanical properties, such as fatigue strength and corrosion resistance [1]. There has been an increased interest in the production of gears using the net-shape forging technique [2][3][4]. The advantages of gear forging include reducing manufacturing costs and saving materials, increasing productivity, and better mechanical properties, compared with conventionally cutting processes [5].…”

Section: Introductionmentioning

confidence: 99%

Modelling and experimental research in hot precision forging of shaft gear

Wang

Zheng

et al. 2015

MATEC Web of Conferences

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Abstract. In this paper, a hot forging die set is designed for a shaft gear. A finite element software DEFORM was employed to simulate the hot forging process. The forming parameter range was determined and the forging force was predicted. The metal flow law in hot forging processes was studied using metal flow analysis and point tracking analysis. The metal flow law was further analysed through finite element simulations and precision forging experiments. The accuracy of hot formed gears is analysed and the deviation of the tooth profile reaches the 8th grade, which meet the defined requirement. The pitch cumulative deviation of the forged part is low enough for practical applications.

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“…Depending on material resistance properties and the size of the formed rims modules, toothing rolling can be realized in cold or hot conditions. However, in majority of cases, these are processes used for external toothing forming [17][18][19][20][21]. Techniques of internal toothing rolling are not popular, which is reflected in the lack of literature concerning this subject.…”

Section: Introductionmentioning

confidence: 99%

Numerical Modelling of the Rolling Process of Internal Toothing of Toothed Wheel Rims

Tomczak¹

2013

Acta Metall Slovaca

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This paper presents results of numerical analysis of rolling process of internal toothing. Numerical simulations of the rolling process were made basing on finite element method (FEM), using commercial software DEFORM-3D in version 10.0. Geometrical models applied in FEM calculations were discussed in details. Calculations were made in three dimensional state of strain with consideration of thermal phenomena. During research works, geometrical parameters of obtained parts were analyzed, distributions of effective strain, effective stress and temperatures as well as the process force parameters were given. Next, the influence of particular process parameters on tools durability and the possibility of presence of phenomena disturbing the process stability were discussed. Described results of numerical research confirm the possibility of forming of internal toothing by means of rolling methods and constitute the introduction for a more complex analysis of metal forming processes of internal toothing.Keywords: toothed wheels, internal toothing, rolling, FEM IntroductionToothed wheels, which mainly constitute elements of drive transmission, are widely applied in machines design [1][2][3][4][5]. Torque transmission takes place in the result of two co-operating wheels meshing and teeth side surfaces interaction. Because of that, the toothed wheels toothing undergoes large loads, often much bigger than loads of other elements. Hence, durability and resistance of the toothed wheels toothing have a crucial influence on machines and devices durability and, in many cases, these elements durability decides about the people safety [6]. Hence, the requirements are very high. The improvement of toothed wheels resistance can be realized in a few ways, for example by application of better materials and appropriate thermomechanical treatment. However, the easiest and cheapest way is appropriate forming of the product internal structure due to the application of semi-finished metal forming. At present, a widely applied way of toothed wheels toothing manufacturing is machining, in which obtaining of a tooth outline is the result of removing of particular material layers [7][8][9][10]. Apart from long tradition, machining processes are relatively expensive and time consuming and they, additionally, lead to weakening of teeth resistance due to material structure rupture. This phenomenon has imposed a search for other unconventional methods of toothing forming. Numerous methods of metal forming of toothed wheels toothing have been worked out, among

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Precision forging processes for high-duty automotive components

Cited by 62 publications

References 6 publications

An investigation of involute and lead deflection in hot precision forging of gears

An investigation of involute and lead deflection in hot precision forging of gears

Modelling and experimental research in hot precision forging of shaft gear

Numerical Modelling of the Rolling Process of Internal Toothing of Toothed Wheel Rims

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