FE prediction method for tooth variation in hot forging of spur bevel gears

Zhuang, Wuhao; Han, Xiaotao; Hua, Lin; Min, Xu; Chen, Mingzhang

doi:10.1016/j.jmapro.2019.01.022

Cited by 21 publications

(7 citation statements)

References 31 publications

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“…Lastly, the simulation outcomes exactly agree with the test outcomes, verifying the FE investigation approach offered in this study [2]. The modeling outcomes explain that in examined situations the distributions of deformation data were inhomogeneous within the forming.…”

Section: Introductionsupporting

confidence: 79%

A Controlled Material Flow Forming Mechanism of Curve Cutter Forging in The Hot Impression Forging of The Medical Instrument

Fuh¹,

Chen²,

Wu³

et al. 2021

Preprint

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In this study, a forming process during producing medical surgery curve cutter stapler would be tentatively as well as numerically investigated and validated by the simulations. The reasons for the investigation are to find the critical technology of the forming process and to understand this medical tool head forming within the forming process associated with medical surgery curve cutter stapler and improve the traditionally forming process. Moreover, to understand the medical tool head forming, the novel forging process, and the parting line approach are offered and simulated by the FE software QForm, the method data on the medical tool head forging are investigated and compared with the experimental analysis. According to the outcomes of the simulations, the distributions of the forming process, some parameters have been gotten to explain and improve these microscopic phenomena. The precision of the numerical patterns has been confirmed by comparing them with the test dimensions. The offered revised model from the forming preform has been submitted to achieve an alike forging condition when reducing manufacturing cost After the improved method, measure the shrinkage width of the workpiece. Compared with the product of the traditional process, the widest area is 6.37mm shrink to 6.29mm. The shrinkage is about 1%. Compared with the previous result is 5%, the improvement plan has been optimized the outcomes very much.

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Section: Introductionsupporting

confidence: 79%

A Controlled Material Flow Forming Mechanism of Curve Cutter Forging in The Hot Impression Forging of The Medical Instrument

Fuh¹,

Chen²,

Wu³

et al. 2021

Preprint

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“…In order to avoid abovementioned macrostructure defects during forging of such components, a large number of scholars have conducted research on improving material flow and adjusting forming load during isothermal forging of complex components. Li [8] proposed a volume pre-distribution and equidistant flow quantitative compensation method for the precision extrusion forming process of complex magnesium alloy rib-web components, which controls the axial material flow, improves the radial material flow and reduces the die cavity resistance. Thiyagarajan [9] used the response surface method to optimize the billets for components such as three-dimensional spring seats and steering linkages, respectively.…”

Section: Fig1 Aircraft Bulkhead Componentmentioning

confidence: 99%

Robust optimization of consistency in filling of rib-grooves for titanium alloy multi-rib eigenstructure

Ding

Yang

et al. 2023

Int J Adv Manuf Technol

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Isothermal forging is an effective method for forming and manufacturing large-scale titanium alloy components with multi-rib. However, successive filling of the rib-grooves and reverse flow of the material are prone to occur during the forming process, which makes those rib-grooves are difficult to be filled then resulting in disturbed material flow and excessive die loading. The variability of billet sizes and fluctuation of uncertain parameters during the forging process have the great impacts on the forming results and stability. To this end, the eigenstructure with multi-rib from large titanium alloy rib-web components was extracted, and the combined method of finite element simulation and physical simulation experiment was used based on isothermal forging technique. Firstly, the finite element model for the eigenstructure under isothermal forging is established, then the behavior of the material flow and rib-grooves filling in the die cavity are analyzed. Secondly, the variation pattern and fluctuation range of rib-grooves filling are investigated by considering the deterministic factors of billet sizes, as well as the uncertainties of die draft angle, forming temperature, forming speed, billet manufacturing deviation and die manufacturing deviation. Subsequently, the significate deterministic factors and uncertainty factors are screened out and the correlation between the mean value as well as the variance of the filling consistency of the rib-grooves and the deterministic factors i.e. billet sizes are established by the dual response surface method. Then, a robust optimization model is constructed and solved. Finally, the reliability of the robust optimization solution is compared and verified, to obtain the ideal and stable fully-filling of the rib-grooves by adjusting and regulating the deterministic factors to weaken the interference of the uncertainties and achieve the simultaneous filling of the rib-grooves.

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“…The material of the error billet is SCM 420, and its chemical composition is given in Table 3. Most research on the dimensional deviation of precision gears primarily focused on the total deviations of tooth helix and profile [18,24]. However, due to the complex structure of the sun gear and the complicated metal flow in the sizing process, the dimensional deviation of the teeth is difficult to control.…”

Section: Simulation and Experiments Preparation 31 Fe Modeling And Pr...mentioning

confidence: 99%

“…The predicted results were in good agreement with the experimental ones. Zhuang et al [18] developed a new FE prediction method to realize the visualization of tooth size change of hot-forged bevel gears. The experimental results show that the prediction method was feasible and reliable.…”

Section: Introductionmentioning

confidence: 99%

Evaluation of Different Tools of Precision Finishing for Sun Gear with Inner-Outer Tooth Shapes

et al. 2022

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Aiming at the technical difficulty of poor teeth accuracy of the extruded sun gears, an innovative precision finishing approach was developed as the subsequent process of producing high-quality sun gears, and three finishing tools were designed, namely mandrel with gap, mandrel without gap and interference mandrel. A finite element prediction method was proposed by using the post-processing toolbox of DEFORM software to study the distribution laws of outer and inner teeth deviations of the reshaped sun gear. Moreover, the effects of various precision finishing tools on the formability of sun gear (such as tooth deformation, tool stress and tooth accuracy) were investigated. The results show that the tooth accuracy class of the reshaped outer teeth in profile and helix were seventh and eighth, respectively, and the total M-value error of the inner teeth was decreased to 72.3 μm and the reduction ratio was 73.8% by adopting the interference mandrel, which indicates that the finishing effect of the interference mandrel was better than that of mandrels for both with gap and without gap, and the forming accuracy of the finished teeth could be considerably improved. Therefore, the interference mandrel can be recommended as the optimum finishing tool in the manufacture of precision sun gears. The simulated results were in good agreement with experimental ones within a maximum error of 14.4%, which proves the practicability of the sizing approach and the dependability of the finite element prediction method.

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FE prediction method for tooth variation in hot forging of spur bevel gears

Cited by 21 publications

References 31 publications

A Controlled Material Flow Forming Mechanism of Curve Cutter Forging in The Hot Impression Forging of The Medical Instrument

A Controlled Material Flow Forming Mechanism of Curve Cutter Forging in The Hot Impression Forging of The Medical Instrument

Robust optimization of consistency in filling of rib-grooves for titanium alloy multi-rib eigenstructure

Evaluation of Different Tools of Precision Finishing for Sun Gear with Inner-Outer Tooth Shapes

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