scholarly journals Numerical Investigation of a New Production Method for Face Gearings Incorporating Material Predistribution – Pin-to-Gear Method

2021 ◽  
Author(s):  
Andre Weiss ◽  
Mathias Liewald
Keyword(s):  
Production Method ◽  
Geometric Constraints ◽  
Width Ratio ◽  
Research Subjects ◽  
Forming Process ◽  
New Production ◽  
Cold Forming ◽  
Process Forces ◽  
Process Reliability ◽  
Deform 2D

The research subjects of current investigations at the Institute for Metal Forming Technology (IFU) Stuttgart include the manufacture of face gearings. Usually, gearings are produced by means of a coining process, which causes high process forces that considerably restrict the geometry of the teeth in terms of the height-to-width ratio. In order to avoid these problems, a new forming process has been developed. This technology offers significant advantages, such as the reduction of process forces and the ability to manufacture the required tall and acuminate tooth elements through a cold-forming process. This paper describes the design and functionality of the novel pin-to-gear forming process. In this paper, the operating principle of the method is presented first of all. The new pin-to-gear process is then compared to conventional coining and the free-divided-flow (FDF) process developed at IFU Stuttgart in 2018. This examination takes the form of a numerical simulation using DEFORM-2D software. To investigate the influence of preform parameters on the form filling of the tooth cavities, parameter studies in design and geometry are conducted. Process limits regarding geometric constraints are presented alongside possibilities for increasing process reliability. Through this investigation, the potential and opportunities of the innovative pin-to-gear forming process will be illustrated.

Grain Size Modification by Micro Rotary Swaging

2015 ◽  
Vol 651-653 ◽  
pp. 627-632 ◽  
Author(s):  
Svetlana Ishkina ◽  
Bernd Kuhfuss ◽  
Christian Schenck
Keyword(s):  
Grain Size ◽  
Longitudinal Section ◽  
Forming Process ◽  
Boundary Area ◽  
Cold Forming ◽  
Flat Surfaces ◽  
Rotary Swaging ◽  
2D Simulation ◽  
Physical Tests ◽  
Formed Part

Rotary swaging is a well established cold forming process e.g. in the automotive industry. In order to modify the material properties by swaging systematically, a new process of swaging with asymmetrical strokes of the forming dies is investigated. The newly developed tools feature flat surfaces and do not represent the geometry of the formed part as in conventional swaging. Numerical simulation and physical tests are carried out with special regard to the resulting geometry, mechanical properties and the microstructure. During these tests copper wires with diameter d0=1 mm are formed. Regarding the microstructure in the longitudinal section of formed specimens, elongation of grains in the central part and grain size reduction in the boundary area are observed. Furthermore, this approach opens up new possibilities to configure the geometry of wires. 2D-simulation is applied and discussed in the paper to investigate change of the processed geometry (cross-section) and shear strain distribution during the rotary swaging process.

Numerical Study of the Flow Forming Process of AISI 630 Stainless Steel

2011 ◽  
Vol 264-265 ◽  
pp. 24-29 ◽  
Author(s):  
Seyed Mohammad Ebrahimi ◽  
Seyed Ali Asghar Akbari Mousavi ◽  
Mostafa Soltan Bayazidi ◽  
Mohammad Mastoori
Keyword(s):  
Feeding Rate ◽  
Surface Defects ◽  
Numerical Study ◽  
Internal Diameter ◽  
The Finite Element Method ◽  
Forming Process ◽  
Flow Forming ◽  
Cold Forming ◽  
External Variables ◽  
Experimental Process

Flow forming is one of the cold forming process which is used for hollow symmetrical shapes. In this paper, the forward flow forming process is simulated using the finite element method and its results are compared with the experimental process. The variation of thickness of the sample is examined by the ultrasonic tests for the five locations of the tubes. To simulate the process, the ABAQUS explicit is used. The effects of flow forming variables such as the angle of rollers and rate of feeding of rollers, on the external variables such as internal diameter, thickness of tube and roller forces are considered. The study showed that the roller force and surface defects were reduced with low feeding rate and low rollers attack angles. Moreover, the sample internal diameter increased at low feeding rate and low rollers attack angles. The optimum variables for flow forming process were also obtained.

Machine Learning Acoustic Emission Based Monitoring of Cold Forging for Smart Manufacturing: A Review

2021 ◽  
Vol 2 (3) ◽  
Keyword(s):  
Machine Learning ◽  
Acoustic Emission ◽  
Product Quality ◽  
High Speed ◽  
High Rate ◽  
Cold Forging ◽  
Smart Manufacturing ◽  
Forming Process ◽  
Cold Forming ◽  
Effective Manner

Cold forging is a high-speed forming technique used to shape metals at near room temperature. and it allows high-rate production of high strength metal-based products in a consistent and cost-effective manner. However, cold forming processes are characterized by complex material deformation dynamics which makes product quality control difficult to achieve. There is no well defined mathematical model that governs the interactions between a cold forming process, material properties, and final product quality. The goal of this work is to provide a review for the state of research in the field of using acoustic emission (AE) technology in monitoring cold forging process. The integration of AE with machine learning (ML) algorithms to monitor the quality is also reviewed and discussed. It is realized that this promising technology didn’t receive the deserving attention for its implementation in cold forging and that more work is needed.

Research of Characteristic of Wrinkling in Cold Forming Process for Ship Frame Part Based on Numerical Simulation

2015 ◽  
Author(s):  
Pei-Yong Li ◽  
◽  
Jun-jie Song ◽  
Cheng-fang Wang ◽  
Yun-sheng Mao ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Forming Process ◽  
Cold Forming

scholarly journals Production organization capacity of ethnic minorities in northwestern region of Vietnam

2020 ◽  
Vol 210 ◽  
pp. 16004
Author(s):  
Thu Trang Vu ◽  
Dung Vu ◽  
Thi Mai Lan Nguyen
Keyword(s):  
Ethnic Minorities ◽  
Shifting Cultivation ◽  
Production Capacity ◽  
Production Method ◽  
Small Scale ◽  
New Production ◽  
Organization Capacity ◽  
Northwestern Region ◽  
Traditional Production ◽  
Production Organization

Survey results of 1,452 people representing families of 6 ethnic minorities in 11 communes of 7 districts in 7 provinces in the Northwest region shows that the production organization capacity of the ethnic minorities surveyed has changed, but still remains many limitations. The change in production capacity of ethnic minorities is reflected in the fact that the majority of families have produced in a new way (know how to use some machines, use new plant varieties and breeds, apply chemical fertilizers, use pesticides, and some agricultural products produced for sale). The limitations of the production organization capacity of ethnic minority families are shifting cultivation, dibbling, rudimentary production tools, low labor productivity, production by small-scale, autarky, shifting cultivation of wandering hilltribes). If comparing between traditional production method and new production method, the traditional production method is still more prevalent. One of the main causes of this situation is that ethnic minorities live in mountainous areas with difficult transportation, so the main cultivation method is shifting cultivation. The application of machines in production faces many difficulties.

scholarly journals Preparation Method of Spherical and Monocrystalline Aluminum Powder

Metals ◽  
2019 ◽  
Vol 9 (3) ◽  
pp. 375 ◽  
Author(s):  
Mateusz Skalon ◽  
Marek Hebda ◽  
Ricardo Buzolin ◽  
Gernot Pottlacher ◽  
Stefan Mitsche ◽  
...  
Keyword(s):  
Silica Nanoparticles ◽  
Aluminum Powder ◽  
Electron Backscatter Diffraction ◽  
High Surface ◽  
Spherical Shape ◽  
Production Method ◽  
Processing Temperature ◽  
Powder Preparation ◽  
New Production ◽  
Aluminum Particles

This paper presents a new production method for a spherical and monocrystalline aluminum powder. Aluminum powder of irregular particle shapes was mixed with silica nanoparticles and heated to a temperature above the melting point of aluminum. Due to its molten state, high surface tension, and poor wettability, the aluminum particles were transformed into liquid and spherical droplets separated by silica nanoparticles. The spherical shape was then retained when the aluminum particles solidified. The influence of the processing temperature on the particle shape, phase composition, and microstructure was investigated. Moreover, calorimetric, X-ray diffraction, grain size, and scanning electron microscopy with electron backscatter diffraction (SEM-EBSD) measurements of the particles’ microstructure are presented. It is proven that, by this means, a spherical and monocrystalline aluminum powder can be efficiently created directly from an air-atomized irregular powder. The observed phenomenon of particles becoming round is of great importance, especially when considering powder preparation for powder-based additive manufacturing processes.

Study on the Formability of the Seam Welded Tube for Manufacturing the Drive Shaft

2013 ◽  
Vol 631-632 ◽  
pp. 708-712
Author(s):  
Bong Joon Kim ◽  
Eun Soo Park ◽  
Won Yong Byeon ◽  
Dal Joon Cha ◽  
Yong Nam Kwon
Keyword(s):  
Weld Line ◽  
Reduction Process ◽  
Rear Wheel ◽  
Drive Shaft ◽  
Cold Reduction ◽  
Roll Forming ◽  
Forming Process ◽  
Cold Forming ◽  
Geometrical Defects ◽  
The Impact

In this study, cold reduction process of the tubular metal is applied to manufacture the drive shaft for the rear wheel drive system. With this method during forming process, chip forming such as hobbing and broaching method is not involved. The manufacturing process is as follows; the tube which the sheet is formed and welded to by roll forming machine, is mounted on a suitable mandrel. This mandrel has an external toothing which corresponds to internal toothing of the final product. During axial moving and rotating of the workpiece, forming operation is carried out in lengthwise direction of the toothing. This forming rolls is positioned on the roll head and have a rolling axis vertical with the one of a mandrel. The total forming load needed in the cold reduction process is separated into numerous forming steps along the entire cylindrical length of the zone to be formed. In the process of cold forming on the profiled mandrel during the impact forming operation, material is pushed into depression of toothing of a mandrel mainly in a radial direction. Finally splines can be generated on the surface of components and overall elongated. If the process parameter such as the length of forming per 1rotation of 1roll is not optimized, the impact force from the rolls of the forming process causes geometrical defects. So the optimal parameters such as feeding and rotating speed of workpiece and the forming length should be properly determined. And the effects of the weld line positioning on the formability of the forming process is analyzed to minimize the generation of the defects such as crack on the surface of splined zone.

Numerical and experimental analysis on cold-forming and spring-back of hull plate

2018 ◽  
Vol 233 (3) ◽  
pp. 561-569 ◽  
Author(s):  
Wei Shen ◽  
Renjun Yan ◽  
Shuangying Li
Keyword(s):  
Three Dimensional ◽  
Dimensional Accuracy ◽  
Ship Hull ◽  
Laser Forming ◽  
Successive Approximation Method ◽  
Spring Back ◽  
Forming Process ◽  
Cold Forming ◽  
Thick Plates ◽  
Forming Mechanism

Ship hull structures are fabricated by curved thick plates before they are welded together. There are traditional methods such as, line heating and laser-forming methods for plate bending. However, it is recognized that the hot-forming technology causes a series of troubles on doubly or multiple curved plates. Multi-point forming mechanism with square press heads is a new forming process for three-dimensional ship hull plate. Cold-forming has a high dimensional accuracy but results in spring-back. The spring-back process of curved thick plates in the finite element method is analyzed and the predicted results are compared with the test results in the present paper. To ensure the forming precision, the successive approximation method is also developed and verified to control the spring-back.

HORIZONTAL DRILLING, A NEW PRODUCTION METHOD

1988 ◽  
Vol 28 (1) ◽  
pp. 41
Author(s):  
Jacques Bosio
Keyword(s):  
World Wide ◽  
Horizontal Wells ◽  
Production Method ◽  
New Production ◽  
Horizontal Drilling ◽  
New Approach ◽  
Flow Geometry ◽  
The Future ◽  
Deviated Wells

Vertical or deviated wells cross a production formation for only short distances. Horizontal wells, however, are capable of remaining within a reservoir for distances up to several hundred metres in an effort to enhance production possibilities.A world-wide coverage of the method will be presented, with the latest information on drilling, logging, completion and costs.Application of horizontal wells will be described with an emphasis on the production results recently obtained and, more particularly, on the Rospo Mare field, offshore, in the Adriatic Sea.Horizontal wells are providing a new approach to the flow geometry within a production formation. There is no doubt that they will be used more and more in the future to optimise the drainage of most reservoirs.

Sign in / Sign up

Export Citation Format

Share Document