Warm forging of an aluminium alloy for the differential case in an automobile transmission

Lee, Sangik; Kim, Byung-Min; Lee, Hye-Jin; Yoon, Jonghun

doi:10.1177/0954407015600900

Cited by 7 publications

(6 citation statements)

References 26 publications

(26 reference statements)

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“…As both gears for this analysis are steel, n ¼ 0. 3 ¼ 4615:38N. The overload factor K OF accounts for externally applied loads in excess of the transmitted load and is set as K OF ¼ 1 for smooth operation.…”

Section: Discussionmentioning

confidence: 99%

“…Moreover, mechanical systems such as transmission systems have replaced steels in low-performance components such as gear box casings, with lightweight aluminium or magnesium alloys. 3 However, in order to continue achieving significant weight savings for vehicles and aircraft in the future, it is essential that the weight reduction philosophy is applied to the mechanical components as well. For the case of transmission systems, the majority of system mass exists in gears, shafts, and bearings, thus reducing mass would involve the reduction in weight of the gears, shafts and bearings themselves.…”

Section: Introductionmentioning

confidence: 99%

“…Moreover, mechanical systems such as transmission systems have replaced steels in low-performance components such as gear box casings, with lightweight aluminium or magnesium alloys. 3…”

Section: Introductionmentioning

confidence: 99%

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An analysis of the tooth stress distribution of forged bi-metallic gears

Politis

Lin

et al. 2016

Proceedings of the Institution of Mechanical Engineers, Part C:

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The work described in this paper is an evaluation of the contact characteristics of bi-metallic gears forged through a novel bi-metallic gear forging process. Finite element analysis of the contact characteristics of single material gears was first performed to validate the tooth contact and tooth root stresses with empirical American Gear Manufacturers Association and British Standard standards. Having verified the validity of the model, simulations were performed for gears comprising lightweight cores with teeth bounded by steel bands of uniform thicknesses, 1 mm, 2 mm, 4 mm, and 6 mm to evaluate the differences in stress distribution and compare to single material gear teeth. The forged profiles obtained experimentally by utilising 2 mm, 4 mm, and 6 mm thickness bands via the bi-metallic gear forging process are also discussed. The uniform thickness model is subsequently adapted to incorporate the experimental forged profiles in order to estimate the contact stress, root stress, and stress distribution within the teeth to identify performance differences between bi-metallic forged gears and traditional single material gears.

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Section: Discussionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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An analysis of the tooth stress distribution of forged bi-metallic gears

Politis

Lin

et al. 2016

Proceedings of the Institution of Mechanical Engineers, Part C:

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“…As a total change instance, the aluminum alloys that a type of low-density materials can be used in the manufacturing of body panels or gearbox casings instead of steel since these components are subjected to low external forces/stresses. 4 Regarding power transmission machine elements, the high strength steel alloys are still the best option with their mechanical, physical, and manufacturability properties. However, partial material change can be possible for this type of component provided that a joining method that ensures the structural integrity of the gear under the loading conditions is found.…”

Section: Introductionmentioning

confidence: 99%

A numerical investigation on the hybrid spur gears: Stress and dynamic analysis

Yılmaz

Doǧan

Karpat

2020

Proceedings of the Institution of Mechanical Engineers, Part C:

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In this study, the effect of rim thickness of hybrid gears on the root stress, joint stress, tooth stiffness, natural frequency, and dynamic behavior are examined numerically. Hybrid gears consist of two materials, which are steel for the teeth-rim and hub regions of gear, carbon fiber reinforced plastic (CFRP) for the web region. Adhesive bonding is assumed for the joining of steel and composite materials. FE method is used to evaluate tooth root stress, joint stress, tooth deformation, and the natural frequency of hybrid gears. The adhesive is defined by cohesive zone modeling (CZM). Moreover, 2-DOF dynamic analyses are implemented to obtain dynamic factors and static transmission error. According to results, hybrid gears have substantial potential to reduce the mass of gear transmission systems with no adverse effect on root stress and dynamic factor if the design parameters are appropriately selected. Besides, rim thickness is found as a critical parameter for the hybrid gears since when its value changes from 0.5xm to 3xm, the root stress decreases 10% while the tooth stiffness and torque capacity increase 20% and 65%, respectively.

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“…Computational tools have been successfully employed in different problems of the automotive industry (Kokkula et al, 2006;Lee et al, 2016;Kong et al, 2016). However, this is not a simple problem and to perform an appropriate representation of the phenomena involved in the heat treatment, a coupled thermo-mechanical-metallurgical model is required.…”

Section: Introductionmentioning

confidence: 99%

Design of the austempering heat treatment of a ductile iron differential case aided by computer simulation

Boccardo

Dardati

Godoy

et al. 2018

Lat. Am. j. solids struct.

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Austempered ductile iron is frequently employed in the fabrication of automobile parts due to its good mechanical properties, and its simplicity and low cost of the manufacturing process. The heat treatment design is an important stage, in which parameters such as temperatures and durations are chosen according to the required microstructure, part dimension, and initial characteristics of ductile iron. A coupled thermo-mechanicalmetallurgical model is employed in this work to facilitate the heat treatment design of a ductile iron differential case. The thermal-mechanical model is solved by using a general-purpose software, and the metallurgical model is implemented into it by means of user-defined subroutines. To perform the austempering heat treatment simulation of the part, experimental results were required to complete some basic parameters of the model. In order to select appropriated values of thermal cycle parameters, the numerical model was employed to analyze the influence of austenitizing temperature, and austempering time and temperature in the microstructure, dimensional change of the part, cooling rate, and minimum required time of the heat treatment to obtain a full ausferritic matrix. A good performance of the computational tool was found by comparison of numerical and experimental results. KeywordsDuctile iron differential case, Austempering heat treatment design, Thermo-mechanical-metallurgical analysis, Finite element analysis.

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Warm forging of an aluminium alloy for the differential case in an automobile transmission

Cited by 7 publications

References 26 publications

An analysis of the tooth stress distribution of forged bi-metallic gears

An analysis of the tooth stress distribution of forged bi-metallic gears

A numerical investigation on the hybrid spur gears: Stress and dynamic analysis

Design of the austempering heat treatment of a ductile iron differential case aided by computer simulation

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