Alternative die designs in net-shape forging of gears

Cai, Jian Hua; Dean, Trevor; Hu, Zhi-Quan

doi:10.1016/j.jmatprotec.2004.01.019

Cited by 69 publications

(36 citation statements)

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“…The selection of billet dimensions and design of the forging tool is very important for the optimization of technological parameters of precision die forging process as well as for forging tool life [15,16]. Two basic alternatives of ring billet dimensions and the shape of die cavity for the production of given drop forging of spur gear have been designed.…”

Section: Resultsmentioning

confidence: 99%

Application of computer simulation at optimization of technological parameters of precision die forging

Kapustova

Görögová

2016

Teh. vjesn.

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Original scientific paper The paper deals with the optimization of technological parameters of precision forging in closed die using computer simulation with the aim to achieve high dimensional accuracy and surface quality of drop forgings. The research has been applied on spur gears with a hub. This type of mechanical part has been chosen because of its wide application in machine industry. Shape of this drop forging is suitable for the precision forging technology, as well. Case hardening steel 16MnCr5 has been selected as a common material used for drop forging production. Computer simulation is a useful solution for prediction of the forging process development and material behaviour in closed die cavity. The numeric simulation has been used for the optimization of billet shape and dimensions and observation of plastic flow in closed die cavity at warm die forging. Suitability of material flow in die cavity, effective plastic strain and temperature of drop forging have been evaluated by means of simulation software Simufact.forming. To meet all requirements on accuracy of drop forgings it is necessary to take into consideration optimization of technological parameters using computer simulation.Keywords: closed die; computer simulation; forgeability; spur gear; precision warm die forging; upsetting test Primjena simulacije računalom u optimizaciji tehnoloških parametara kod preciznog kovanjaIzvorni znanstveni članak Rad se bavi optimizacijom tehnoloških parametara kod preciznog kovanja u zatvorenom kalupu primjenom simulacije računalom s ciljem postizanja visoke dimenzionalne točnosti i kvalitete površine otkivaka dobivenih kalupnim kovanjem. Istraživanje se provodilo na čelnicima s ravnim zubima s glavinom. Taj je tip strojnog dijela izabran zbog njegove široke primjene u strojarstvu. Oblik takvog otkivka također je pogodan za tehnologiju preciznog kovanja. Čelik za kaljenje 16MnCr5 odabran je kao materijal za proizvodnju kalupnim kovanjem. Simulacija računalom je korisno rješenje za predviđanje odvijanja postupka kovanja i ponašanja materijala u zatvorenoj šupljini kalupa. Numerička simulacije je primijenjena u optimizaciji oblika i dimenzija trupca te promatranja plastičnog tečenja u zatvorenoj šupljini kod kovanja u kalupu. Odgovarajući tok materijala u kalupu, učinkovita plastična deformacija i temperatura kalupnog kovanja procijenjeni su pomoću simulacijskog softvera Simufact.forming. Kako bi se zadovoljili svi zahtjevi vezani za točnost otkivaka dobivenih kalupnim kovanjem potrebno je uzeti u obzir optimizaciju tehnoloških parametara primjenom simulacije računalom. Ključne riječi:

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Section: Resultsmentioning

confidence: 99%

Application of computer simulation at optimization of technological parameters of precision die forging

Kapustova

Görögová

2016

Teh. vjesn.

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“…According to Eqs. (8) and (9), the effects on the elastic die expansion contain the dimensions of the die, namely, R 1 , R 2 , and R 3 , and inner pressure, σ s . R 1 is a parameter relative to the root circle of the gear and is not a variable.…”

Section: Theoretical Analysismentioning

confidence: 99%

“…The benefits of low forging force include low distortion, improved dimensional accuracy, and long tool life [8]. An alternative die design was proposed by Cai et al [8] to enhance filling of the bottom corners of teeth. They also proposed a chamfered punch to reduce forming load.…”

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

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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 injection upsetting method was one of the bulk forming methods and is specialized to form intricate shapes. And, for metal forming operations forming load is the most important parameter and so, it is important to estimate the forming load for the metal forming processes for optimal die design and selecting press capacity [3,7,9,14]. Mathematical methods are getting used more commonly in recent years to simulate the forming load and other process parameters which affect the quality of the product and it is possible to obtain optimum die design.…”

Section: Introductionmentioning

confidence: 99%

Simulation of Helical Gear Forming of Az31 Magnesium Material

Ayer¹

2017

Adv. Sci. Technol. Res. J.

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The simulation of helical gear forming is investigated in this study. AZ31 type magnesium material was selected for workpiece material because of its high specific strength. The finite element method was used to simulate the closed die upsetting method for magnesium material of helical gear upsetting. Three dimensional finite element analyses were carried out to obtain the forming load, effective stress, effective strain and temperature change with DEFORM-3D software.

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Alternative die designs in net-shape forging of gears

Cited by 69 publications

References 1 publication

Application of computer simulation at optimization of technological parameters of precision die forging

Application of computer simulation at optimization of technological parameters of precision die forging

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

Simulation of Helical Gear Forming of Az31 Magnesium Material

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