Development of a non-isothermal forging process for hollow power transmission shafts

Pang, Hao; Ngaile, Gracious

doi:10.1016/j.jmapro.2019.08.034

Cited by 15 publications

(5 citation statements)

References 18 publications

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“…Upsetting is another widely used method for forming hollow products. Pang et al [9][10][11] proposed a novel method for forming a hollow flanged part from a tube. The process involved heating a tube section first and then deforming it into a rod by upsetting the workpiece wall.…”

Section: Introductionmentioning

confidence: 99%

Analysis of a New Process for Forming Two Flanges Simultaneously in a Hollow Part by Extrusion with Two Moving Dies

Winiarski,

Gontarz,

Skrzat

et al. 2024

Metals

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This paper presents a new method for forming flanges in hollow parts. The process consists of an extrusion with two dies that move in an opposite direction to that of the punches. This particular kinematics of the tools makes it possible to form two flanges simultaneously in a single tool pass. The proposed method was investigated using a tube made of steel 42CrMo4. It was assumed that the extrusion would be conducted as a cold forming process at ambient temperature. Different diameters and heights of the impression made in the top and bottom dies were used. It was demonstrated that the main failure mode of the proposed technique was an unintended increase in the inside the diameter of the workpiece in the flange zone. The results showed that the above parameters had a key impact on the achievable maximum flange diameters and heights.

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Section: Introductionmentioning

confidence: 99%

Analysis of a New Process for Forming Two Flanges Simultaneously in a Hollow Part by Extrusion with Two Moving Dies

Winiarski,

Gontarz,

Skrzat

et al. 2024

Metals

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“…Shaft parts occupy a key role in automobile transmission systems, and one of the best ways to reduce the weight of these components will be to design and manufacture them as hollow components [ 1 ]. Forming processes, especially those based on short-chain lightweight design of shaft parts, are an effective solution to reduce the vehicle weight, thus saving energy in the vehicle’s long service life cycle [ 2 ].…”

Section: Introductionmentioning

confidence: 99%

Effect of Rotary Swaging on Mechanical Behaviors of Axle Steel Rod

Tian,

Xu,

Zheng

et al. 2024

Materials

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The short-chain forming process using rotary swaging (RS) is an important method of achieving the manufacturing of lightweight axles. Axle steel, like 42CrMo, is widely used in many types of axles and shafts; however, there is no existing research on rotary-swaged axle steel’s mechanical properties. It makes sense to carry out a comprehensive study on the effect of RS on the mechanical behaviors of axle steel rods. In this study, a 42CrMo steel rod was processed by RS through ten passes. The tensile properties, torsion properties, compression properties, and fatigue properties were tested. There was an overall improvement in the torsional and fatigue performance after RS. Combined with a finite element analysis (FEM), the uneven distribution of the dislocations and existence of the elongation material were inferred to have caused the different modes of the mechanical behaviors. Fracture surfaces were analyzed and the results showed that the fracture pattern had changed. There existed a competitive relation between the internal fatigue cracks and external cracks, which could be attributed to uneven strain hardening. This research proved the advantages of RS in the processing of axle parts, which mainly benefitted the torsional working conditions, and provided evidence for a new processing route for lightweight axles with RS.

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“…Recent studies on upsetting processes for tubes have focused on the design of new upsetting methods or modification of the existing methods to increase their efficiency. For example, Pang et al [28][29][30] developed a non-isothermal forging process for producing transmission shafts. In this process, the first operation involves heating a tube section which is then subjected to upsetting in a cylindrical die cavity.…”

Section: Introductionmentioning

confidence: 99%

Theoretical and Experimental Study on the Effect of Selected Parameters in a New Method of Extrusion with a Movable Sleeve

Winiarski

2022

Materials

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This paper presents a new method for forming hollow flanged products. The method involves extrusion with the use of a sleeve moving in the opposite direction to that of the punch. A tube with a constant hole diameter and two different outside diameters, made of aluminum alloy EN AW 6060 was used as a material. Numerical calculations were performed using Deform 2D/3D. Experiments were conducted on the PYE 160SS hydraulic press equipped with a specially designed device in which the punch is driven by the press slide while the moveable sleeve is driven by two hydraulic servomotors. Both numerical simulations and experiments were conducted under cold forming conditions. The aim of this study was to determine the effect of selected parameters (flange diameter, height of the cavity in the moveable sleeve, and the chamfer angle between the regions with different outside diameters on the workpiece and in the moveable sleeve cavity) on the stability of the extrusion process. Results were then used to undertake detailed comparative analyses of underfill, flange heights, and flange flank inclination angles. Findings of the analyses served as a basis for drawing conclusions regarding the effect of the analyzed parameters on the investigated extrusion process.

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Development of a non-isothermal forging process for hollow power transmission shafts

Cited by 15 publications

References 18 publications

Analysis of a New Process for Forming Two Flanges Simultaneously in a Hollow Part by Extrusion with Two Moving Dies

Analysis of a New Process for Forming Two Flanges Simultaneously in a Hollow Part by Extrusion with Two Moving Dies

Effect of Rotary Swaging on Mechanical Behaviors of Axle Steel Rod

Theoretical and Experimental Study on the Effect of Selected Parameters in a New Method of Extrusion with a Movable Sleeve

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