The prediction of maximum forging load and effective stress for different material of bevel gear forging

Abstract

The manufacture of gears by applying hot or cold bulk forming processes is a quite widespread production method due to its well-known basic advantages such as material and time cost reduction and the increased strength of the teeth. However, the associated process planning and tool design are more complicated. In the precision forging of gears, the workpiece volume, the die design, the power requirement and careful processing are more critical than traditional forging technology. For complete filling up, predicting the power requirement is an important feature of the near net-shape forging process. In this paper, a finite element analysis is utilized to investigate the material properties such as yielding stress, strength coefficient and strain hardening exponent effects on forming load and maximum effective stress. The adductive network was then applied to synthesize the data set obtained from the numerical simulation. The predicted results of the maximum forging load and maximum equivalent stress of bevel gear forging from the prediction model are consistent with the results obtained from FEM simulation quite well. After employing the prediction model one can provide valuable references in prediction of the maximum forging load and maximum equivalent stress of bevel gear forging under a suitable range of material parameters.

Integrated modelling of hot forging of low-alloyed steels for an ICME workflow

“…This leads to a reduction in recrystallization fraction for the same amount of strain applied [Eq. (11)]. Apart from that, the increased strain-rate also leads to finer grain sizes in the completely recrystallized regions [Eq.…”

“…Therefore, to obtain the desired properties, it is necessary to carefully design the process to yield the required microstructure distribution in the final product. Traditionally, process design in the context of hot forging has majorly been limited to address issues such as die designing [1,2], reducing underfill [3], avoiding possible defects [4][5][6], flash design [7][8][9], forging load [10][11][12] and more recently microstructure evolution [13][14][15][16][17]. Often, these approaches focus primarily on the deformation sub-step design without paying much attention on the role of the process in the larger product development workflow which includes material selection, other upstream and downstream processes and final property requirement.…”

Sustainable and green manufacturing and materials design through computations

“…The upper bound elemental technique used for process design of axisymmetric forging operations is also worth notable. 25 Some of the practical applications of computations for analyzing aeroengine components, bevel gear forging, and powder metallurgy components can be understood from the work of Ou et al, Yang et al, and Planitzer et al [26][27][28] Deep drawing. The sheet forming processes involve plastic deformation of sheets to make parts used as house hold utensils, in automotive, and aerospace industries.…”

Volumetric and Graphical Presentation of Stress-Strain State of the Aluminium Billet at Realization of the Forging Process.

“…The forging process in the die is similar to the casting process. Metal in solid state is deformed and begins to flow, filling the die cavities [1][2][3][4][5][6][7][8][9][10]. In this case, strain velocity will vary over the entire time range of the forging process in the entire volume of metal.…”