Finite Element Analysis and Optimization of Deformation Behavior for Spur Gear Warm Forging Process

2010 ◽  
Vol 148-149 ◽  
pp. 854-858
Author(s):  
Shu Bo Xu ◽  
Cai Nian Jing ◽  
Ke Ke Sun ◽  
Guo Cheng Ren ◽  
Gui Qing Wang
Keyword(s):  
Finite Element ◽  
Spur Gear ◽  
Spur Gears ◽  
Element Analysis ◽  
Helical Gears ◽  
Forging Process ◽  
Precision Forging ◽  
Die Forging ◽  
Closed Die Forging ◽  
Warm Forging

Recent years have therefore seen growing interest in gear precision forging to net-shape form of forge bevel, spur and helical gears, as an alternative to conventional manufacturing. In this paper, gear precision forging processes are simulated by using metal forming finite element code DEFORM-3D. The investigations of gear precision forging processes are conducted with perform forging and final forging processes. The processes of completely closed-die forging, moving-die forging and central divided flow forging processes are investigated for spur gears. The effect of different processes on the distribution of effective stress in the workpieces and forging loads are given. The purpose of this study is to introduce a new method, a so-called floating-relief method which applied to the forging of spur gears. It indicated that the flowing properties of the gear billet have a higher improve than that of conventional forging process. And the forging load obtained by using this new precision forging technology is decline sharply. The floating-relief method for gear precision forging is a sound process in the practical application.

Numerical Simulation on Precision Forging Process for Spur-Gear with Large Module

2012 ◽  
Vol 538-541 ◽  
pp. 927-931
Author(s):  
Gui Hua Liu ◽  
Zhi Ping Zhong ◽  
Yi Bian ◽  
Qian Li
Keyword(s):  
Numerical Simulation ◽  
Finite Element Method ◽  
Finite Element ◽  
Material Flow ◽  
Spur Gear ◽  
Cold Extrusion ◽  
Forging Process ◽  
Precision Forging ◽  
Warm Forging ◽  
Forging Force

The whole precision forging process of spur-gear with large module (module: 4) including warm forging, cold extrusion and cold sizing is analyzed. By using finite element method, cold sizing step of spur-gear basing on hollow-divided-flow method is simulated, the influenc of hollow diameter on the forging force and material flow is discussed in detail. Futher research shows that appropriate different tooth reduction is benefit to forming tooth profile without mechaning after forging. According to the research, to form such spur gear with module 4 and breadth 59mm studied in this paper, the hollow diameter should be 18mm and the tooth reduction should be 1.2mm. The necessary reference and basis to realize practical precision forging process of spur gear with large module is provided eventually.

scholarly journals A Method of Selecting Grid Size to Account for Hertz Deformation in Finite Element Analysis of Spur Gears

1982 ◽  
Vol 104 (4) ◽  
pp. 759-764 ◽  
Author(s):  
J. J. Coy ◽  
C. Hu-Chih Chao
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Gear Tooth ◽  
Spur Gear ◽  
Grid Size ◽  
Spur Gears ◽  
Element Analysis ◽  
Element Size ◽  
Full Effect ◽  
The Finite Element Analysis

A method of selecting grid size for the finite element analysis of gear tooth deflection is presented. The method is based on a finite element study of two cylinders in line contact, where the criterion for establishing element size was that there be agreement with the classic Hertzian solution for deflection. Many previous finite element studies of gear tooth deflection have not included the full effect of the Hertzian deflection. The present results are applied to calculate deflection for the gear specimen used in the NASA spur gear test rig. Comparisons are made between the present results and the results of two other methods of calculation. The results have application in design of gear tooth profile modifications to reduce noise and dynamic loads.

Simulation and Experiment of Cold Forging for Spur Gear Based on Local Loading

2011 ◽  
Vol 268-270 ◽  
pp. 241-246 ◽  
Author(s):  
Feng Xu ◽  
Ke Min Xue ◽  
Ping Li ◽  
Dong Mei Gong ◽  
Gang Chao Wang ◽  
...  
Keyword(s):  
Spur Gear ◽  
Cold Forging ◽  
Spur Gears ◽  
Stress Distributions ◽  
Local Loading ◽  
Forming Technology ◽  
Die Forging ◽  
Closed Die Forging ◽  
Simulation And Experiment ◽  
Physics Experiment

The cold closed-die forging of spur gears brings the problems of great forming forces , low life of the dies and insufficent corner filling. The two-step forming technology is presented. First, the billet is pre-forged by closed-die forging for getting most of tooth profile. Second, the gear is finish-forging by local loading. The finite element method is used to simulate the cold forging process.The strain distributions, the stress distributions, velocity distributions and load-stroke curve are investigated.. The simulation results show that the technology can guarantee the full filling effect, and decrease the forming force remarkably. The results of simulation and analysis were verified by the physics experiment.

scholarly journals Finite Element Analysis of a Spur Gear Considering Mass Relief Strategies

2021 ◽  
Vol 31 (2) ◽  
pp. 36-49
Author(s):  
Lauro Miguel Lima Rocha ◽  
Marco Túlio Santana Alves
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Local Stress ◽  
Spur Gear ◽  
Spur Gears ◽  
Element Analysis ◽  
The Core ◽  
Core Thickness ◽  
Structural Influence ◽  
Maximum Stresses

This paper deals with analyzing the structural influence of mass reliefs in spur gears. For this purpose, a system composed of pinion and a gear was designed, such that for gear several geometries were designed with different reliefs shapes and soul thicknesses. From the proposed geometries, finite element analysis (FEA) was performed, and the tooth stresses of each model were compared with the solid gear. From the results, it was observed that the tooth stresses are reduced in some cases. Besides, from the aforementioned cases, it is possible to observe that the maximum stresses may take place in its core instead of the teeth (rim area). On the other hand, based on other cases, the core thickness plays an important role as a criterion that defines the local stress.

Investigation of Precision Forging Process of Spur Gears: Numerical Analysis and Experiments

2011 ◽  
Vol 341-342 ◽  
pp. 265-270
Author(s):  
M. Zadshakoyan ◽  
E.Abdi Sobbouhi ◽  
H. Jafarzadeh
Keyword(s):  
Numerical Analysis ◽  
Effective Strain ◽  
Spur Gear ◽  
Model Material ◽  
Optimum Number ◽  
Spur Gears ◽  
Specific Pressure ◽  
Rigid Plastic ◽  
Forging Process ◽  
Precision Forging

In this study, the precision forging process of spur gears has been investigated by means of numerical analysis. The effect of some parameters such as teeth number and module on the forming force and specific pressure were presented. The simulation works were performed rigid-plastic finite element method using DEFORM 3D software. In order to validate the estimated numerical results, they were compared with those obtained experimentally during precision forging of spur gear using lead as a model material. Results showed that the optimum number of gear teeth is between 10 to 20, that is because of being the specific pressure in its minimum value. Also the results obtained from analyzing the effective strain distribution showed that the maximum strain is located on the root area of the teeth. The work presented in this paper might be used for basic data in the design of the precision forging process.

The New Preforging Method of Closed-Die Forging with Controlled-Flash for Steering Knuckles

2012 ◽  
Vol 482-484 ◽  
pp. 2409-2413
Author(s):  
Lian Jun Cheng ◽  
Tie Zhu Zhang ◽  
Hong Xin Zhang
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Utilization Rate ◽  
3D Finite Element ◽  
Key Technology ◽  
Forging Process ◽  
Die Forging ◽  
Closed Die Forging ◽  
3D Finite Element Method ◽  
Material Utilization

In this paper, the new forging process for forming the steering knuckle of the truck is proposed, which includes preforming, preforging and finish-forging. The key technology of new forging process is focused on the preforging design. The closed-die forging with controlled-flash process for the preforging is proposed, by which the material utilization rate is enhanced greatly. The proper preforming includes three steps: rod extrusion, fork flatting and cleaving. The 3D finite element method (FEM) for simulation the forging process is also presented. The new and the traditional forging processes of producing the steering knuckle are compared too.

Comparison of Bending Stress of a Spur Gear for Different Materials and Modules Using AGMA Standards in FEA

2013 ◽  
Vol 739 ◽  
pp. 382-387 ◽  
Author(s):  
S. Prabhakaran ◽  
S. Ramachandran
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Three Dimensional ◽  
Element Model ◽  
Spur Gear ◽  
Spur Gears ◽  
Element Analysis ◽  
Dimensional Finite Element ◽  
Three Dimensional Finite Element ◽  
Element Method

Gearing is one of the most critical components in mechanical power transmission systems.. This paper explains about the comparison of the geometry of spur gears for two different modules by modeling and mathematical equations, load distribution at various positions of the contact line and the stress analysis of spur gears using three-dimensional finite element method. The bending stresses were examined using three-dimensional finite element model.. These stresses of different modules obtained from the finite element analysis were compared and the considerable reduction of weight occurred was found and also the values are compared with the theoretical values. Both results agree very well. This indicates that the finite element method model is accurate.

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