Forming of light-weight gear wheel by plate forging

Wang, Z.G.; Hirasawa, Katsuyoshi; Yoshikawa, Yasuharu; Osakada, Kozo

doi:10.1016/j.cirp.2016.04.134

Cited by 29 publications

(4 citation statements)

References 2 publications

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“…As a crucial transmission component, spur gears nd extensive application in automobiles and diverse mechanical equipment [1][2][3]. With the rapid development of the automotive industry, there is an increasing demand for high-quality gear processing and longer service life in automotive parts [4][5][6].…”

Section: Introductionmentioning

confidence: 99%

Simulation study of the punching forming process and die wear of spur gears

Chen,

Guo,

Fang

et al. 2024

Int J Adv Manuf Technol

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As an important transmission component, the spur gear has been widely used in automobiles and various mechanical equipment. However, spur gears are produced by the hobbing and shaving, which inevitably reduces the service strength and service life of the gear. In this paper, the punching forming process of spur gear is presented. Compared with the traditional gear machining process, the process not only avoids the destruction of the metal ow line and signi cantly improves the material utilization rate. The effect of tooth lling and equivalent strain accumulation on gear forming quality were discussed by nite element simulation. The effects of upper die punching speed, lower die preheating temperature and friction coe cient on lower die wear during forming were studied by response surface method. The optimum process parameters of punching of spur gear were lower die preheating temperature of 280℃, friction coe cient of 0.27, upper die feed speed of 8.3 mm/s, respectively.It is predicted that about 110,000 gears can be produced before the wear failure of the lower die. On the basis of the nite element simulation results, the gear punching test is carried out. The experimental results are in good agreement with the simulation results, and the metal ow line at the tooth is uniform and continuous, which veri es the reliability of the punching process. This study provides a feasible way for plastic forming of spur gear.

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Section: Introductionmentioning

confidence: 99%

Simulation study of the punching forming process and die wear of spur gears

Chen,

Guo,

Fang

et al. 2024

Int J Adv Manuf Technol

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“…With the increase in interest, as well as the frequency of use of gears, designing a gearbox for the required conditions has become a demanding task [13][14]. Today, automotive components, particularly rotating parts in the powertrain-including gears-are designed to be as light as possible, to reduce fuel consumption and thus CO 2 emissions, among other things [15][16]. First of all, reducing the weight of the gear transmission is important in household appliances, where the gears are obtained by injection methods from polymer materials, in which reducing their weight is important for saving material while maintaining durability and wear resistance while ensuring proper cooperation, where the disc affects the meshing conditions.…”

Section: Introductionmentioning

confidence: 99%

Static Analysis of Selected Design Solutions for Weight-Reduced Gears

Dziubek¹,

Sobolewski²,

Budzik³

et al. 2022

Adv. Sci. Technol. Res. J.

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The paper presents an analysis of selected design solutions for spur gears with reduced weight, in which the results obtained are compared to a solid gear without modifications. The reduction of the weight of the gears is of particular importance, among others in the automotive and aviation industries, where it reduces energy consumption, and thus CO 2 emissions. It is also important to remember to maintain the required strength parameters when reducing the mass of the gear. This article focuses on the analysis of deformation and stress due to a given load on the considered weight-reduced gears. The values of the obtained static analysis results of the reduced-weight gears were also compared to the base gear.

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“…Plate forging and bulk sheet forming of metal parts, which can replace conventional heavy parts, of electric and/or electronic devices have been ongoing for two decades [1][2][3][4]. Additionally, the forging of high-strength and/or lightweight materials has been intensively researched [5][6][7][8]. New car-friendly materials and applications have emerged.…”

Section: Introductionmentioning

confidence: 99%

Automatic Multi-Stage Cold Forging of an SUS304 Ball-Stud with a Hexagonal Hole at One End

Byun

Razali

Lee³

et al. 2020

Materials

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SUS304 stainless steel is characterized by combined tensile and compression testing, with an emphasis on flow stress at higher strain and temperature. The plastic deformation behavior of SUS304 from room temperature to 400 °C is examined and a general approach is used to express flow stress as a closed-form function of strain, strain rate, and temperature; this is optimal when the strain is high, especially during automatic multi-stage cold forging. The fitted flow stress is subjected to elastothermoviscoplastic finite element analysis (FEA) of an automatic multi-stage cold forging process for an SUS304 ball-stud. The importance of the thermal effect during cold forging, in terms of high material strength and good strain-hardening, is revealed by comparing the forming load, die wear and die stress predictions of non-isothermal and isothermal FEAs. The experiments have shown that the predictions of isothermal FEA are not feasible because of the high predicted effective stress on the weakest part of the die.

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Forming of light-weight gear wheel by plate forging

Cited by 29 publications

References 2 publications

Simulation study of the punching forming process and die wear of spur gears

Simulation study of the punching forming process and die wear of spur gears

Static Analysis of Selected Design Solutions for Weight-Reduced Gears

Automatic Multi-Stage Cold Forging of an SUS304 Ball-Stud with a Hexagonal Hole at One End

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