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.

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

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.

Optimization of the Isothermal Forging Process of a Spur Bevel Gear

2016 ◽  
Vol 878 ◽  
pp. 28-32 ◽  
Author(s):  
Xin Hai Zhao ◽  
Dan Dan Liu ◽  
Xing Hui Wang ◽  
Xiang Hong Wu
Keyword(s):  
Experimental Method ◽  
Deformation Temperature ◽  
Bevel Gear ◽  
Isothermal Forging ◽  
Forging Process ◽  
Forming Load ◽  
Suitable Parameter ◽  
Folding Defect ◽  
Optimum Technology

In this paper, the optimization of the parameters of the isothermal forging technology to form spur bevel gear was studied. The goal of the optimization is to decrease the forming load during the process. Then, some factors included the ratio of height to diameter of billet, thickness and position of punching recess, deformation temperature and velocity were taken as the optimization values and the orthogonal experimental method was employed to carried out the optimization. After the optimization, a set of optimum technology parameters were obtained. The result demonstrates that the precise spur bevel gear can be formed with less forming load and without causing under-filling and folding defect by using the isothermal forging and choosing suitable parameter, which provides reference to form the spur bevel gear.

Modeling and Numerical Simulation Research on Hollow Steel Ingot Forging Process of Heavy Cylinder Forging

2013 ◽  
Vol 712-715 ◽  
pp. 627-632
Author(s):  
Min Liu ◽  
Qing Xian Ma
Keyword(s):  
Numerical Simulation ◽  
Grain Size ◽  
Shear Zone ◽  
Grain Refinement ◽  
Steel Ingot ◽  
Effective Strain ◽  
Meridian Plane ◽  
Forging Process ◽  
Forming Load ◽  
Average Grain Size

Aiming at the disadvantages of low utilization ratio of steel ingot, uneven microstructure properties and long production period in the solid steel ingot forging process of heavy cylinder forgings such as reactor pressure vessel, a new shortened process using hollow steel ingot was proposed. By means of modeling of lead sample and DEFORM-3D numerical simulation, the deformation law and grain refinement behavior for 162 ton hollow steel ingot upsetting at different reduction ratios, pressing speeds and friction factors were investigated, and the formation rule of inner-wall defects in upsetting of hollow steel ingots with different shape factors was further analyzed. Simulation results show that the severest deformation occurs in the shear zone of meridian plane in the upsetting process of hollow steel ingot, and the average grain size in the shear zone is the smallest. As pressing speed increases, the forming load gradually increases and the deformation uniformity gets worse, while the average grain size decreases. An increase in friction factor can increase the peak value of effective strain, but it significantly reduces the deformation uniformity, increases the forming load and goes against grain refinement. Moreover, the four kinds of defects on the inner wall of steel ingot can be eliminated effectively by referring to the plotted defect control curve for hollow steel ingot during high temperature upsetting.

scholarly journals Modelling Closed-Die Forging Operations Using Total Lagrangian Smooth Particle Hydrodynamics

2019 ◽  
Author(s):  
Anthony Manson
Keyword(s):  
Large Deformation ◽  
Smooth Particle Hydrodynamics ◽  
Material Flows ◽  
Forging Process ◽  
Mesh Free ◽  
Closed Die Forging ◽  
Particle Hydrodynamics ◽  
Mesh Free Method ◽  
Large Material ◽  
Simulation Parameters

Total Lagrangian Smooth Particle Hydrodynamics (TLSPH) has been applied to a set of non-trivial, commercially interesting forging examples.Being a mesh-free method, TLSPH can conveniently simulate processes having large deformation and material separation.Test cases were designed that were characterized by large material flows having large changes in grain connectivity.The implementation used, Smooth Mach Dynamics (SMD), provided tunable simulation parameters that enabled the simulation to optimally match each case.The results showed that the TLSPH/SMD has the potential to model the metal forging process efficiently without numerical instabilities.Each case studied required adaptation of the simulation parameters to optimize the results.

Claw-Pole Closed Forging Process

2014 ◽  
Vol 912-914 ◽  
pp. 605-608 ◽  
Author(s):  
Xuan Rong Xin ◽  
Ding Xu ◽  
Cheng Song He ◽  
Xin Cheng Liu
Keyword(s):  
Mass Production ◽  
New Technology ◽  
Extrusion Process ◽  
Forming Force ◽  
Short Life ◽  
Forging Process ◽  
New Process ◽  
Corner Filling ◽  
Hot Die Forging ◽  
Deform 3D

Aimed at the present domestic problems in the forging process of claw pole, such as insufficient corner filling, excessive forming force and short life of dies. On the basis of the analyzing in the claw pole, a new process named the closed hot die forging, direct extrusion process of claw pole is constituted. The numerical simulation using DEFORM-3D and the special mould are used in the forging experiment in order to check the new process. The results show that, new technology has greatly reduced the forming force, thereby reducing the production processes and improving the life of dies for mass production.

scholarly journals Closed Die Forging of Mg-Al-Zn-Ca-Y Alloys

2018 ◽  
Vol 918 ◽  
pp. 28-33 ◽  
Author(s):  
Nikolaus Papenberg ◽  
Stefan Gneiger
Keyword(s):  
Mechanical Properties ◽  
Oxidation Behaviour ◽  
Automotive Applications ◽  
Forging Process ◽  
Weight Saving ◽  
Closed Die Forging ◽  
Forged Parts ◽  
Superior Mechanical Properties ◽  
Low Mass ◽  
Materials Used

In light of emission reduction and weight saving in transport applications, Mg parts gain alot attention due to their good specific mechanical properties and their low mass. While casting is themain process for manufacturing Mg parts for automotive applications, forged parts show some majorbenefits like superior mechanical properties and absence of porosity. In this work a comparison ofclosed die forged parts made from different Mg-alloys has been carried out. The materials used in thewarm forging process were AZ31 and various Mg-Al-Zn-Ca-Y type (AZXW) alloys. Ca additions areknown to improve the oxidation behaviour and the formability of magnesium alloys, while yttrium isused to enhance the flammability resistance of forged parts. The forgeability, mechanical propertiesand microstructure are analyzed and compared in the present paper.

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