Study of elastic deformation on dimensional accuracy in ironing process of spur gear

2016 ◽  
Vol 232 (3) ◽  
pp. 513-524 ◽  
Author(s):  
Yan Gao ◽  
Rui Zhou ◽  
Yu-Cheng Wu ◽  
Heng-Li ◽  
Wen-Lin Chen ◽  
...  
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Elastic Recovery ◽  
Gear Tooth ◽  
Dimensional Accuracy ◽  
Spur Gear ◽  
Compensation Method ◽  
Elastic Behavior ◽  
Thick Wall ◽  
Element Simulation

The cold ironing process of a warm forged spur gear was applied to investigate the elastic distortions arising by the behavior of die elastic expansion and gear elastic recovery in this article. An elasto-plastic finite element simulation was performed to analyze the elastic behavior characteristics of gear and die. The effects of interference between gear and die on the elastic distortions were investigated through finite element simulation and experiment, respectively. The change of geometrical profile and dimension of the gear tooth were measured; the estimated dimension of ironed gear by finite element simulation was fitted to the experimental results well within the range of 5% relative error. Furthermore, in order to improve the dimensional accuracy of final forged gear, this study proposed a die cavity compensation method to compensate cavity of the ironing die, which was obtained by shrink fitting a outer ring into the initial ironing die. The optimum radial interference between stress ring and initial shrink-fitted die was calculated based on the Lame formula and thick wall cylinder theory. Finally, an experiment according to the proposed die cavity compensation method was carried out to examine the validity of analytical results and demonstrated that predicted dimensions could be achieved and dimensional accuracy greatly improved. It was shown that the manufacture gear satisfies the IOS6 class by measuring the iron-forged gear.

Finite Element Simulation of Bending Stress on Involute Spur Gear Tooth Profiles

2017 ◽  
Vol 30 ◽  
pp. 1-10
Author(s):  
Kolawole Adesola Oladejo ◽  
Dare Aderibigbe Adetan ◽  
Ayobami Samuel Ajayi ◽  
Oluwasanmi Oluwagbenga Aderinola
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Gear Tooth ◽  
Spur Gear ◽  
Bending Stress ◽  
Relative Deviation ◽  
Element Simulation ◽  
Maximum Relative Deviation ◽  
Bending Stresses ◽  
Good Agreement

This study investigated bending stress distribution on involute spur gear tooth profiles with pressure angle of 20 ̊ but different modules 2.5, 4.0 and 6.0 mm, using a finite-element-based simulation package - AutoFEA JL Analyzer. The drafting of the geometry for the three gear tooth profiles were implemented on the platform of VB-AutoCAD customized environment, before importing to the package. These were separately subjected to analysis for bending stresses for a point at the tooth fillet region with appropriate settings of material property, load and boundary conditions. With the same settings, the bending stresses were computed analytically using American Gear Manufacturers Association (AGMA) established equation. The results of the two approaches were in good agreement, with maximum relative deviation of 4.38%. This informed the confidence in the implementation of the package to investigate the variation of bending stress within the gear tooth profile. The simulation revealed decrease in the bending stresses at the investigated regions with increase in the module of the involute spur-gear. The study confirms that Finite element simulation of stresses on gear tooth can be obtained accurately and quickly with the AutoFEA JL Analyzer.

Finite Element Simulation as a Tool to Evaluate Gear Quality after Gear Rolling

2013 ◽  
Vol 554-557 ◽  
pp. 300-306 ◽  
Author(s):  
Alireza Khodaee ◽  
Arne Melander
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Gear Wheel ◽  
Spur Gear ◽  
Interesting Case ◽  
Shape Accuracy ◽  
Good Surface ◽  
Element Simulation ◽  
Gear Wheels ◽  
Gear Rolling

Gear rolling is a manufacturing technique for gears with many advantages like reduced material consumption, reduced scrap generation, fast cycle times, good surface quality and improved final properties of the gear wheels compared to conventional production technology based on machining. In order to make use of all these advantages it is desired to reach the final shape of the gear wheel already after rolling. This means that post treatments like grinding should be avoided. This puts high requirements on the shape accuracy after gear rolling. In this paper it was studied if finite element simulation could be used to evaluate the shape accuracy after gear rolling. The measurement of shape accuracy of gear wheels is specified in standards like ISO1328-1. The allowed deviations from nominal shape are often of the order of 10-30 μm for very good qualities. So if such evaluation shall be possible from a finite element simulation the accuracy must be of the same order. In order to have sufficient accuracy of the finite element simulation 2D simulations were performed on a spur gear. The FE code DEFORM was utilized. The shape accuracy was evaluated for gear rolling of two cases. One case had gears with the module of 1 mm. The other case involved gears with a significantly larger module of 4 mm. This was an interesting case since it is known that it is more difficult to roll the gear with good accuracy in large modules.

Forming Analysis of Housing with Small Fillets

2011 ◽  
Vol 80-81 ◽  
pp. 601-605
Author(s):  
Peng Yuan ◽  
Han Guan Xia ◽  
Xin Cun Zhuang ◽  
Hong Jun Zhao ◽  
Yi Dong ◽  
...  
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Metal Forming ◽  
Dimensional Accuracy ◽  
Housing Production ◽  
Bulk Metal ◽  
Bulk Metal Forming ◽  
Process Sequence ◽  
Element Simulation ◽  
Forming Analysis

In order to ensure the dimensional accuracy of housing with small fillets, various forming factors have been analyzed in this paper based on finite element simulation. Through the analysis of the forming factors, the principle of die angle selection, the proper reverse drawing height in sizing process, sequence of sizing and applications of local sheet bulk metal forming in housing production were put forward, and some forming laws of housing with small fillets were concluded.

Springback Analysis of Sheet Metals Regarding Material Hardening

2005 ◽  
Vol 6-8 ◽  
pp. 721-728 ◽  
Author(s):  
Marco Schikorra ◽  
R. Govindarajan ◽  
Alexander Brosius ◽  
Matthias Kleiner
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Dimensional Accuracy ◽  
Material Behavior ◽  
Experimental Investigations ◽  
Sheet Metals ◽  
Forming Process ◽  
Element Simulation ◽  
Strain Reversal ◽  
Draw Bending

The phenomenon of springback of thin-walled sheet metal parts after forming is a well known problem of forming technology in general, but particularly since the finite element simulation offers the opportunity to predict geometrical and material properties after forming. Irrespective of the intensive efforts in the previous years, a reliable and accurate prediction of springback deviations by use of the finite element simulation is still not possible. This paper deals with the numerical and experimental analysis of the springback effect itself, which dependents on the final stress states of a part after the forming process. Experimental investigations have been carried out to analyze geometrical accuracy in loaded and unloaded conditions to isolate the springback effect. Additional finite element simulations have been conducted in order to compare the experimental and numerical results and to determine the geometrical differences and their reasons. Two experimental set-ups are being discussed: Air bending on the one hand, which offers good access to the specimen in the testing equipment, and draw bending on the other hand, which is characterized by a simple strain state, but also by strain reversal within the tests. Both experiments were carried out using DP600 and X5CrNi18.10 with three different sheet thicknesses and bend radii and were compared with according FE-models. An additional shear test experiment has been developed to characterize the material behavior of the tested sheet metals for strain reversal. Furthermore, the importance of the Bauschinger effect and usable hardening models were analyzed. This study intended to investigate reasons for insufficient form and dimensional accuracy between simulations and experiments after springback and to propose modeling methods to improve the accuracy.

scholarly journals Analysis of Tooth Surface Contact Stress of Involute Spur Gear

2021 ◽  
Vol 2133 (1) ◽  
pp. 012037
Author(s):  
Yusheng Zhai ◽  
Jie Mu ◽  
Ruiguang Yun ◽  
Siran Jia ◽  
Jianfeng En ◽  
...  
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Contact Stress ◽  
Simulation Analysis ◽  
Spur Gear ◽  
Tooth Surface ◽  
Analysis Model ◽  
Element Analysis ◽  
Element Simulation ◽  
Surface Contact

Abstract Through the establishment of a pair of spur gear contact models, based on Hertz contact theory, the tooth surface contact stress is calculated; then the Ansys finite element analysis software is used to simulate and analyse the stress distribution. Through the analysis and comparison of the two results, it is proved that the contact stress calculated by Hertz theory is relatively small, which is close to the results of the finite element simulation analysis. Theoretical calculation can verify the accuracy of the finite element simulation analysis model, and the finite element simulation analysis provides an effective way to accurately calculate the contact stress of the tooth surface.

scholarly journals Analysis of Dimensional Variations of Precision Gear Forging Die Geometry Due to Shrink Fit

2018 ◽  
Vol 2 (3) ◽  
pp. 87
Author(s):  
Omer Eyercioglu
Keyword(s):  
Finite Element ◽  
Shape Change ◽  
Gear Tooth ◽  
Spur Gear ◽  
Thick Wall ◽  
Experimental Measurements ◽  
Fe Model ◽  
Shrink Fitting ◽  
Shrink Fit ◽  
Forging Die

The usual way to shrink fit design for precision forging dies are made by thick wall cylinder approach; i.e., taking the pitch diameter of the gear as bore diameter of the die insert without considering gear tooth shape. However, the compressive pre-stress due to the shrink fitting causes dimensional variations on the gear profile of the die insert. The dimensional accuracy of the final product is dependent on the accuracy of the gear die. Therefore, the dimensional variations due to shrink fit must be pre-determined and the gear tooth profile on the die insert modified accordingly. In this study, the dimensional variations of the precision spur gear forging die because of shrink fitting are analyzed by finite element method and the results are compared with the experimental ones. The results show that the FE model is successful to simulate the cylindrical die and agree well with thick wall cylinder approach and the experimental measurements. However, both the experimental measurements and the finite element results of gear die predict much higher radial displacements than the results of cylindrical die. Therefore, the determination of shape change of the gear die profile is beyond the capability of the thick wall cylindrical approach.

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