Numerical investigations of multicomponent process lightweight design for joining gearwheels by lateral extrusion

Meissner, Robert; Liewald, Mathias

doi:10.1051/matecconf/20168013005

Cited by 3 publications

(6 citation statements)

References 8 publications

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“…1). The difference between the inner and outer envelope is called eccentricity e. The inner profile contains six 2 mm deep cavities in radial direction to enable a form and force fit in tangential and axial direction [14].…”

Section: Manufacturing Of Multicomponent Gear Wheel By Lateral Extrusionmentioning

confidence: 99%

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Influence of Lubrication on Manufacturing of Multicomponent Gear Wheels by Lateral Extrusion

Meissner

Liewald

2018

KEM

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A combination of several manufacturing process steps in a simultaneous manner allows to save energy costs, reduce investment and economic logistical efforts. This paper provides the contribution reports on particular research work performed by the Institute for Metal Forming Technology, which deals with gearwheel bodies manufactured by lateral extrusion (forging). The scope of this paper focuses on the joining process and achievement of desired properties for forged wheel bodies. At the beginning of the forming process, a blank is placed in a ring having an axial and tangential profile. Due to a force application on the face surface, the material flows into the ring radially and in the following, the joint provides both a form and press fit. Since the forming and joining process is conducted in one step, the lubricant for the forming process must fulfil two requirements. First, low friction for the manufacturing process is advised. On the contrary, the joint gearwheel needs to transmit the applied load during use. In order to determine the influences of two different lubricants onto both the manufacturing processes and static torque application, experimental investigations were performed

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Section: Manufacturing Of Multicomponent Gear Wheel By Lateral Extrusionmentioning

confidence: 99%

“…Previous research work investigated influence of the inner gear ring profile on punch force and material flow. Geometric parameters of tool and blank regarding material flow [14] and the tool concept used in the following study resulted from this research [15].…”

Section: Manufacturing Of Multicomponent Gear Wheel By Lateral Extrusionmentioning

confidence: 99%

Influence of Lubrication on Manufacturing of Multicomponent Gear Wheels by Lateral Extrusion

Meissner

Liewald

2018

KEM

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“…Apart from these small areas, the Two simulations were conductedthe forging process in DEFORM 3D and a subsequent structural analysis in ANSYS. The forging process uses the tool geometry described in [6].…”

Section: Introductionmentioning

confidence: 99%

“…This leads to varying inner diameters between 73 mm and 77 mm. The inner profile contains six 2 mm deep cavities in radial direction to enable a form and force fit in tangential and axial direction[6].A tool in a one-stage hydraulic press performs the actual joining process (figure 3). Placing the gear ring between six preloading die segments prevents impermissible tangential tension stress in the gear ring during and after forming.…”

mentioning

confidence: 99%

“…In order to obtain a symmetric homogenized lateral extrusion process on a one-stage hydraulic press, using a hydraulic closing device, equipped with hydraulic chamber and nitrogen storages, is necessary.Previous research investigated the influences of the inner gear ring profile on punch force and material flow. Geometric parameters of tool and blank regarding material flow[6] and the tool concept resulted from this research[7].…”

mentioning

confidence: 99%

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Manufacturing processes of multi-component gearwheels

Meissner

Benkert

Hiller

et al. 2017

Forsch Ingenieurwes

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Gearwheels in automotive applications are usually designed as monolithic parts. Adapting the concept of multi-component design to those applications allows to reduce the car's weight. The presented multi-component gearwheels consist of three pieces: a gear ring including teeth, a shaft and a wheel body that connects shaft and gear ring. Two gearwheel concepts as well as the corresponding joining strategy of gear ring and wheel body are introduced in this paper. First manufacturing concept is about the wheel body stapled by fine blanked sheet metal layers. Gear ring and wheel body are joined by a press fit. The second concept focuses on manufacturing the wheel body by lateral extrusion of a metal disk. Using the gear ring as the die in the forging tool allows manufacturing the wheel body as well as joining wheel body and gear ring simultaneously. The authors investigate both production processes virtually and compare both gearwheels designs regarding load and lightweight potential.

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