scholarly journals Preform Optimization for Bevel Gear of Warm Forging Process

Procedia CIRP ◽  
2018 ◽  
Vol 72 ◽  
pp. 340-345 ◽  
Author(s):  
Hong-Seok Park ◽  
Febriani Risky Ayu ◽  
Saurabh Kumar
Keyword(s):  
Bevel Gear ◽  
Forging Process ◽  
Preform Optimization ◽  
Warm Forging

Preform Optimization of Functional Bevel Gear for Warm Forging Processes

2020 ◽  
Vol 21 (5) ◽  
pp. 1097-1106
Author(s):  
Risky Ayu Febriani ◽  
Hong Seok Park ◽  
Saurabh Kumar ◽  
Chang Myung Lee
Keyword(s):  
Bevel Gear ◽  
Preform Optimization ◽  
Warm Forging

Numerical Simulation and Experimental Study on Warm Forging Process of Half Axle Bevel Gear

2011 ◽  
Vol 291-294 ◽  
pp. 774-777
Author(s):  
Ying Tong
Keyword(s):  
Bevel Gear ◽  
Damage Factor ◽  
Forming Force ◽  
Good Test ◽  
Forging Process ◽  
Forming Load ◽  
Closed Die Forging ◽  
Minimum Stress ◽  
Warm Forging ◽  
Stress Damage

According to the shape character of half axle bevel gear forging a process based on closed-die forging scheme was proposed. Based on a series of simulation the influence of initial forging temperature on forming force, the influence of web thickness and web position on stress, damage factor and forming force were analyzed. According to numerical analysis the web dimensions and forging temperature which ensure a minimum stress, a minimum damage factor and a proper forming load were achieved. The forming result was simulated and evaluated, and the forming load was controlled under 760ton. At last the research project got good test verifying.

Numerical Simulation Analysis on Cold Closed-Die Forging of Differential Satellite Gear in Car

2008 ◽  
Vol 575-578 ◽  
pp. 517-524 ◽  
Author(s):  
Yao Zong Zhang ◽  
Jian Bo Huang ◽  
Xue Lin ◽  
Quan Shui Fang
Keyword(s):  
Numerical Simulation ◽  
Simulation Analysis ◽  
Simulation Software ◽  
Bevel Gear ◽  
Cold Forging ◽  
Forging Process ◽  
Die Forging ◽  
Closed Die Forging ◽  
Forming Defects ◽  
Deform 3D

The cold closed-die forging process of the gear is a kind of new technique of the precise forming of gear in recent years. In this paper, the cold closed-die forging process of differential satellite gear in car was analyzed through numerical simulation method. Forming mold was designed with Pro/E Wildfire2.0 which included four components : upper punch, lower punch, tooth shape upper die and lower die for Normal Cone. The three-dimensional models of satellite bevel gear mould were built and imported into numerical simulation software DEFORM-3D. Because the gear has the uniform circumferential features, in order to save time and improve the accuracy, only one tooth was simulated, and the full simulation outcome of 10 teeth was mirrored from this one. Through the numerical simulation analysis of DEFORM-3D, the instantaneous deformation and stress filed were gained. Forming defects were forecasted and the cold closed-die forging rule for satellite gear used in car was obtained which can provide effective references for no-flash cold forging process of planet bevel gear and the mold design.

One Action Press Forming of Helix Bevel Gear by Using Multi-Cylinder Press and Die Heating System

2018 ◽  
Vol 12 (5) ◽  
pp. 767-774
Author(s):  
Katsuaki Nakamura ◽  
◽  
Hiroshi Koresawa ◽  
Hiroyuki Narahara
Keyword(s):  
Hot Forging ◽  
High Hardness ◽  
Heating System ◽  
Bevel Gear ◽  
Cold Forging ◽  
Machining Time ◽  
Forging Process ◽  
Forged Parts ◽  
Almost All ◽  
Forging Press

In the case of a complex shaped helix bevel gear, the forging of complete gear tips is very difficult to achieve. In almost all cases, tooth profile is finished by cutting machine from simple shaped forged parts, therefore requiring considerable machining time and cost. However, there are many approaches to forging. Forging is mainly classified as hot and cold forging, and uses a single motion press. In the case of hot forging takeoff of products from die is difficult by the cooling shrinkage from die and accuracy of products is lower level than cold forging. In addition, in the case of cold forging, a complicated shape is difficult to achieve based on the lack of ductility of the materials. To realize a helix bevel gear using a single forging operation, we applied a tool heating system and three-axis forging press. The tool heating system is applied to prevent a temperature decrease in the material by contact between the tool and forging material during the forging process. Further, to optimize the forging direction and timing, we used a three-axis forging press. We confirmed good forging capability of this special forging process, as well as the high precision of the forged parts. Moreover, through the thermo-mechanical control of steel and the tool temperature, the forged parts showed good mechanical properties, such as high hardness.

Precision Forging Process Analysis and Preform Optimization of Small Compressor Blade of Titanium Alloy

2013 ◽  
Vol 364 ◽  
pp. 493-499 ◽  
Author(s):  
Wen Chen Xu ◽  
De Bin Shan ◽  
Wei Feng Zhang ◽  
Yan Lu
Keyword(s):  
Titanium Alloy ◽  
Process Analysis ◽  
Compressor Blade ◽  
Geometric Shape ◽  
Compressor Blades ◽  
Forging Process ◽  
Dimensional Precision ◽  
Precision Forging ◽  
Preheating Temperature ◽  
Preform Optimization

Small compressor blades of titanium alloy are important mechanical structural components of advanced aircraft engines. In the present study, the preheating scheme and the forging process of the small compressor blade were modeled by the commercial software DEFORM3D and the forging experiments were conducted on a 10,000KN screw press. The results show that the reasonable preheating temperature for the small blade should be controlled in 960-970°C. The geometric shape and size of the blade preform influenced not only overlap and underfilling defects but also the dimensional precision of small compressor blade forgings. On this basis, the optimized geometric shape of the blade preform was obtained and the compressor blades were well formed by limited forging process experiments.

FE simulation as a must tool in cold/warm forging process and tool design

2000 ◽  
Vol 98 (2) ◽  
pp. 143-149 ◽  
Author(s):  
Hyunkee Kim ◽  
Tetsuji Yagi ◽  
Masahito Yamanaka
Keyword(s):  
Fe Simulation ◽  
Tool Design ◽  
Forging Process ◽  
Warm Forging

FE-Based Design of a Forging Tool System for a Hybrid Bevel Gear

2017 ◽  
Vol 742 ◽  
pp. 544-551 ◽  
Author(s):  
Bernd Arno Behrens ◽  
Anas Bouguecha ◽  
Christian Bonk ◽  
Martin Bonhage ◽  
Anna Chugreeva ◽  
...  
Keyword(s):  
Material Flow ◽  
Complex Geometry ◽  
Bevel Gear ◽  
Forging Process ◽  
Material Characterisation ◽  
Forming Technology ◽  
Local Material ◽  
Process Route ◽  
Tailored Forming ◽  
Initial Results

Multi-material solutions offer numerous benefits producing tailored-made hybrid components with enhanced application-optimized properties contrary to conventional monolithic parts. However, designing of corresponding manufacturing processes is often challenging due to various technical aspects. This paper represents a process route for the manufacturing of a hybrid bevel gear by means of tailored forming technology with a focus on die forging and describes the main challenges within the forming stage. Due to local material-specific properties, uncommon material flow and complex geometry of the final part, an individual forming tool system with a geared die was accurately designed. Besides the forming tool system, the FE-based design of the forging process as well as the necessary material characterisation will be presented. Finally, the initial results of the experimental forging investigations are shown.

Recent advances in cold and warm forging process modeling techniques: selected examples

1994 ◽  
Vol 46 (1-2) ◽  
pp. 253-274 ◽  
Author(s):  
Rajiv Shivpuri ◽  
Sailesh Babu ◽  
Satish Kini ◽  
Praveen Pauskar ◽  
Anand Deshpande
Keyword(s):  
Process Modeling ◽  
Forging Process ◽  
Recent Advances ◽  
Modeling Techniques ◽  
Warm Forging

Closed Hot Precision Forging Process of a Bevel Gear with Large Cone Angle

2010 ◽  
Vol 154-155 ◽  
pp. 143-146
Author(s):  
Dong Sheng Ji ◽  
Xin Yun Wang ◽  
Lei Deng ◽  
Ju Chen Xia
Keyword(s):  
Cone Angle ◽  
Element Model ◽  
Bevel Gear ◽  
Optimal Process ◽  
Mechanical Coupling ◽  
Forging Process ◽  
Precision Forging ◽  
Simulation Results ◽  
Large Cone Angle ◽  
Reliable Basis

The closed hot precision forging process of a bevel gear with large cone angle was studied. According to the structure features of the bevel gear, two types of relief forging processes were proposed. First, simulations based on thermal-mechanical coupling finite element model were performed with Deform3D. Then the corresponding experiments were conducted and the results perfectly matched the simulation results. The advantages and deficiencies of two processes were discussed and a reliable basis for selecting the optimal process was proposed.

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