Novel approach in cold forging for efficient manufacturing of shaft-hub-assemblies

Meissner, Robert; Liewald, Mathias; Weiss, André; Deliktas, Tahsin

doi:10.1063/1.5112588

Cited by 2 publications

(3 citation statements)

References 10 publications

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“…The investigated gearwheel has 40 teeth (z), the module (m) 2 mm, base diameter (db) 84.57 mm, tooth root diameter (dtr) 85.08 mm, outside diameter (do) 95.35 mm and a pitch diameter (d) 90.00 mm. This gear wheel geometry is based on the project "massiverLeichtbau" and was also used by Meißner [8]. The GMF-Samanta process was iteratively optimized by successive numerical simulations using Deform 3D™.…”

Section: Simulation Setupmentioning

confidence: 99%

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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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Section: Simulation Setupmentioning

confidence: 99%

“…1b; [6]). In order to overcome these disadvantages, the conventional Samanta process was optimized at the Institute for Metal Forming Technology in Stuttgart by an innovative die design [7,8].…”

mentioning

confidence: 99%

Cold forging of gear components by a modified Samanta process

Weiss

Deliktas

Liewald

et al. 2020

Forsch Ingenieurwes

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“…While cold forging is conventionally used for the manufacturing of symmetrical parts [8] such as bolts [9] or shafts [10], the production of more complex part geometries like screw wrenches [11], hex flange nuts [12] or gear rings for wheel-shaft assemblies [13] is currently being researched. This has been made possible by developments in materials, coatings and process design [14].…”

Section: Introductionmentioning

confidence: 99%

Analysis of stress pins for the local prestressing of cold forging tools

Killmann

Merklein

2020

Prod. Eng. Res. Devel.

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The trend towards lightweight design leads to an increasing demand for sophisticated part geometries with high functional integration. In order to use the advantages of cold forging regarding the time- and resource-efficient production of high-quality parts, high local stresses causing fatigue failure in geometrically complex tools have to be controlled. The objective of this manuscript is to analyse the use of stress pins for a local influence on the stress state within forging, especially in non-circular symmetrical cold forging dies. For this purpose, a closed-die forging process for elliptical parts is designed and analysed regarding the die stresses. Distinct areas with local compressive and tensile stresses occur in the process. To counteract the tensile stresses critical for fatigue failure, the effect of stress pins pressed into the die creating a local prestress is analysed. Around the pins, compressive radial and tensile tangential stresses occur. While large pin diameters, interferences and close positioning to the tensile area lead to an increasing prestressing effect, too high values of these parameters cause a detrimental superposition of tensile process and pin stresses. If used correctly, there is high potential to improve the stress state and tool life especially for locally stressed complex tools.

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Novel approach in cold forging for efficient manufacturing of shaft-hub-assemblies

Cited by 2 publications

References 10 publications

Cold forging of gear components by a modified Samanta process

Cold forging of gear components by a modified Samanta process

Analysis of stress pins for the local prestressing of cold forging tools

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