Improvement strategies for the formfilling in incremental gear forming processes

Sieczkarek, Peter; Wernicke, Sebastian; Gies, S.; Tekkaya, A. Erman; Krebs, Eugen; Wiederkehr, Petra; Biermann, Dirk; Tillmann, Wolfgang; Stangier, Dominic

doi:10.1007/s11740-017-0764-1

Cited by 15 publications

(4 citation statements)

References 13 publications

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“…An incremental gear forming process by means of double-wedge gear tooth punch was provided [20]. Then, his group analyzed the differences between incipient and repeatable material ow in incremental SBMF of gears, and investigated three in uencing factors aiming for a form lling progress of the rst tooth element and an improvement of the teeth heights [21,22].…”

Section: Introductionmentioning

confidence: 99%

A New Successive Forming Process for Large Modulus Gears

Yao

Wang

2020

Preprint

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A successive tooth forming process for producing large modulus spur gears (m＞2.5 mm) was firstly proposed in this paper to break the restrictions of large forming load and large equipment structure of traditional plastic forming. It contains the preforming stage and finishing stage. In the first stage, the die with a single-tooth preformed gear teeth one by one through several passes. In the second stage, the other die with multi-teeth refined the preformed teeth into required shape. The influence of total pressing depth and feed distribution in preforming stage on final forming quality was analyzed by numerical simulation and the reasonable process parameters had been presented. Gears without fold defects were well formed both in simulations and experiments, proving the feasibility of this method. The new process has advantages of smaller forming load and simpler tooling set, which shows a good potential for manufacturing large modulus spur gears.

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Section: Introductionmentioning

confidence: 99%

A New Successive Forming Process for Large Modulus Gears

Yao

Wang

2020

Preprint

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“…An indenter with the final gear form is pressed to the semi-finished products. This process allows avoiding the conventional hardening and heat treatment [12][13][14].…”

Section: Introductionmentioning

confidence: 99%

2D–3D Digital Image Correlation Comparative Analysis for Indentation Process

et al. 2019

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Nowadays, localized forming operations, such as incremental forming processes, are being developed as an alternative to conventional machining or forming techniques. An indentation process is the main action that takes places in these forming activities, allowing small, localized deformations. It is essential to have the knowledge of the material behavior under the punch and the transmitted forces to achieve correct control of the entire procedure. This paper presents the work carried out with the digital image correlation (DIC) technique applied to the study of the material flow that takes place under an indentation process. The material flow analysis is performed under 2D and 3D conditions, establishing the methodology for the calibration and implementation for each alternative. Two-dimensional DIC has been proven to be a satisfactory technique compared with the 3D method, showing results in good agreement with experimental tests and models developed by the finite element method. Notwithstanding, part of the indented material flows under the punch, emerging on the front surface and generating a dead zone that can only be addressed with a 3D technique. So, the main objective is to carry out a comparison between the 2D and 3D techniques to identify if the 3D application could be mandatory for this type of process. Also, a 2D-3D mix analysis is proposed for study cases in which it is necessary to know the material flow in that specific area of the workpiece.

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“…Sieczkarek [3]. These studies have shown that improved die filling, a decrease in die load and punch forces can be accomplished by the use of a preform.…”

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confidence: 99%

Cold forging of gear components by a modified Samanta process

Weiss

Deliktas

Liewald

et al. 2020

Forsch Ingenieurwes

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Cold forging of toothed components by extrusion is associated with high punching forces and tool loads, which requires the use of expensive and high-strength tool steels. High process forces result into a substantial tool deflection, which significantly reduces the precision of the toothed components. Thus, the development of alternative processes in order to reduce acting process forces in cold forging is of high interest. A potential process enhancement approach is to use a preform operation where the resulting preform can be formed partwise either in the same or in a subsequent die. Preforms allow to systematically control the material flow in subsequent forming operations. For this reason, the Institute for Metal Forming Technology in Stuttgart has developed a new cold extrusion process for manufacturing toothed components based on the conventional Samanta process. The newly developed die design of the Guided Material Flow-Samanta (GMF-Samanta) process enables efficient cold forging of gears. By means of numerical simulations and forging experiments it was successfully demonstrated that the new Guided Material Flow-Samanta process results into a significant reduction of punch force and normal pressure while simultaneously improving the die filling. Kaltfließpressen verzahnter Komponenten in einem modifizierten Samanta-Verfahren Konferenzbericht Zusammenfassung Das Kaltfließpressen verzahnter Komponenten ist mit hohen Stempelkräften und Werkzeugbelastungen verbunden, wodurch der Einsatz kostenintensiver und hochfester Werkzeugstähle erforderlich ist. Hohe Prozesskräfte führen zudem zu einer erheblichen elastischen Werkzeugdeformationen, welche die Form-und Maßgenauiugkeit der verzahnten Komponenten signifikant vermindert. Daher ist die Entwicklung alternativer Verfahren zur Reduktion der wirkenden Prozesskräfte in der Kaltmassivumformung von hohem Interesse. Ein möglicher Ansatz zur Prozessverbesserung ist die Anwendung einer Vorformoperation, bei der die resultierende Vorform am Werkstück entweder im gleichen oder in einem nachfolgenden Werkzeug weiter umgeformt werden kann. Vorformen ermöglichen es, den Materialfluss in der nachfolgenden Umformoperationen systematisch zu steuern und damit eine gezielte Reduktion der Reibfläche zwischen Werkstück und Werkzeug herbeizuführen. Aus diesem Grund hat das Institut für Umformtechnik in Stuttgart ein neues Kaltfließpressverfahren zur Herstellung von verzahnten Bauteilen entwickelt, das auf dem konventionellen Samanta-Prozess basiert. Die neuartige Fließpressmatrize des Guided Material Flow-Samanta (GMF-Samanta)-Verfahrens ermöglicht ein effizientes Kaltfließpressen von Verzahnungen. Mittels numerischer Simulationen und experimentellen Umformversuchen konnte erfolgreich nachgewiesen werden, dass das neue Guided Material Flow-Samanta-Verfahren zu einer signifikanten Reduktion der Stempelkraft und der Kontaktspannungen im Werkzeug bei gleichzeitiger Verbesserung der Formfüllung führt.

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Improvement strategies for the formfilling in incremental gear forming processes

Cited by 15 publications

References 13 publications

A New Successive Forming Process for Large Modulus Gears

A New Successive Forming Process for Large Modulus Gears

2D–3D Digital Image Correlation Comparative Analysis for Indentation Process

Cold forging of gear components by a modified Samanta process

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