Investigation on Billets and Tools Geometry in Cold Forging of the Straight Bevel Gear

Van, Duy Dinh; Vu, Duc Quang

doi:10.18517/ijaseit.12.2.15977

Cited by 3 publications

(1 citation statement)

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“…In order to manufacture accurate gear components, the cold forge industry is directing its focus to near-net shape components obtained by cold forging dies [1,2]. Therefore, the die accuracy, and especially, the surface texture is of utmost importance, since all the process severity will be focused on the cold forging tool demanding low friction coefficient and wear resistance, once the material flows into the die and is not assisted with heating.…”

Section: Introductionmentioning

confidence: 99%

Influence of sequential machining process on the surface topography of dies

Bordin,

Builes,

Costa

et al. 2024

Surf. Topogr.: Metrol. Prop.

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Near net-shape manufacturing of components is a trend that aims to significantly reduce machining times and material waste, trading the machining efficiency for smaller lead times. Cold forging of gear-shaped components is one such operation that generates a component with superior geometrical accuracy and precision, however, the machined cavity is often subject to high mechanical loads and fatigue failures. The usual manufacturing chain involves hard machining, die-sinking electro-discharge machining, and mechanical polishing with abrasive media. Without proper knowledge of the resulting surface roughness and morphology, the tribological aspects of the surface can be neglected. Therefore, this study aims to investigate the manufacturing chain of gear-shaped cavities in terms of surface roughness, surface morphology, and surface residual stresses generated after die-sinking electro-discharge machining (roughing and finishing regimes), as well as mechanical polishing. The surface of the gear tooth was evaluated in three distinct regions: flank, top, and bottom. The results showcased that, even though the surface roughness/texture of the different regions of interest illustrates similar magnitudes, the surface morphology presented completely adverse features, highlighting the importance of a thorough analysis of the machined surface. Residual stress analysis indicated that the mechanical polishing operation was not enough to remove the high-magnitude tensile residual stresses.

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Section: Introductionmentioning

confidence: 99%

Influence of sequential machining process on the surface topography of dies

Bordin,

Builes,

Costa

et al. 2024

Surf. Topogr.: Metrol. Prop.

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An Investigation into Forming of Gears Using Rotary Forging Process

Abd-Eltwab,

Elsyed Ayoub,

El-Sheikh

et al. 2024

Manufacturing Technology

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Computational Methodology for the Development of Wrinkled Tubes by Plastic Deformation

Soares,

Silva,

Fonseca

2024

Applied Sciences

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Traditional methods for wrinkled tubes involve welding processes and additional elements, such as plates, screws, rivets, and guides. Considering all the limitations of these processes, this work aims to propose a methodology that allows for maximising the manufacturing process of carbon steel tube joints with seaming using cold forming and minimising the cost of the final product. Therefore, the present work aims to develop a computational model, based on the finite element method, to optimise the deformation process of T6 Aluminium tubes (ø 45 × ø 38.6 mm) with a length of 120 mm. The method uses a steel die with cavities to achieve wrinkled tubes by a forming process. This numerical study was carried out using the Ansys® 2022 R2 software. A nonlinear material and an incremental structural analysis were used. The applied methodology allowed the optimisation of process parameters, the application of forces during tube deformation, the geometry of the die cavity, boundary conditions, and mesh discretisation. Numerical modelling was carried out using the axial symmetry of the assembly (tube–die), enabling a simplified and efficient execution of the final tube geometry. The results were analysed based on the maximum pressure applied to the tube, and the vertical and horizontal displacements of the deformed component, thus obtaining the tube flow with complete filling inside the die cavity at the end of deformation. The die geometry that produced the best results presented a cavity with a radius of curvature of 3 mm, 6 mm in height, and with a depth of 4 mm. The optimised result of the die geometry generated satisfactory results, with the displacement on the x-axis of the tube of approximately 2.85 mm, ensuring the filling of the cavity at the end of the process. For this, the maximum pressure exerted on the tube was approximately 374 MPa.

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Investigation on Billets and Tools Geometry in Cold Forging of the Straight Bevel Gear

Cited by 3 publications

References 0 publications

Influence of sequential machining process on the surface topography of dies

Influence of sequential machining process on the surface topography of dies

An Investigation into Forming of Gears Using Rotary Forging Process

Computational Methodology for the Development of Wrinkled Tubes by Plastic Deformation

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