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.

Optimization Analysis of A7075 Bicycle Stem Forging Process

2013 ◽  
Vol 554-557 ◽  
pp. 227-233
Author(s):  
Dyi Cheng Chen ◽  
Jiun Ru Shiu ◽  
Jheng Guan Lin
Keyword(s):  
Load Distribution ◽  
Effective Strain ◽  
Design Parameters ◽  
Analysis Software ◽  
Rigid Plastic ◽  
Optimization Analysis ◽  
Element Analysis ◽  
Forging Process ◽  
Precision Forging ◽  
Plastic Deformation Behavior

This research analyzes an innovative forging mold design for the various bicycle stem. The paper used the rigid-plastic finite element analysis software and structural analysis to investigate the plastic deformation behavior of aluminum alloy A7075 workpiece for forging process. Under various forging conditions, it analyses the effective strain, the effective stress, the temperature changing, surface pressure, mold radius load distribution, stress analysis of billet and mold. Moreover the paper used the Taguchi method combine the algorithm method of artificial neural network to find out the best design parameters. The paper hoped to offer some tolerance um precision forging manufacture knowledge for industry.

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.

Three-Dimensional Numerical Simulation and Forming Investigation for Net-Shape Forging of Spur Gears

2010 ◽  
Vol 139-141 ◽  
pp. 626-629
Author(s):  
Shu Bo Xu ◽  
Cai Nian Jing ◽  
Gui Qing Wang ◽  
Guo Cheng Ren
Keyword(s):  
Numerical Simulation ◽  
Three Dimensional ◽  
Spur Gear ◽  
Systematic Investigation ◽  
Spur Gears ◽  
Stress Distributions ◽  
Forging Process ◽  
Precision Forging ◽  
Finite Element Numerical Simulation ◽  
Forging Die

In this paper, a new precision forging technique composite processing of the moving-die forging and divided flow forging process to form the spur gear is introduced. A systematic investigation of the floating-relief method process is performed by using finite element numerical simulation. The stress distributions on the workpieces were obtained. The closer the die teeth corner is, the higher stress value results can be acquired. And the effective stress is concentrated in spur gears forging die cavity corner. It was found that the floating-relief method forging process with upper and lower convex punches control the material flow effectively and the tooth cavity is filled successfully during the performing forging and final forging. The proposed method can serve as preconditions to analyze the abrasion and fatigue of spur gears forging die. The obtained results can offer valuable guidelines for gear precision forging experiments and practical process planning.

Study on the Large Module Spur Gear Cold Forming Process by Means of Numerical Simulation

2011 ◽  
Vol 189-193 ◽  
pp. 2642-2646 ◽  
Author(s):  
Qian Li ◽  
Yi Bian ◽  
Zhi Ping Zhong ◽  
Gui Hua Liu ◽  
Ying Chen
Keyword(s):  
Numerical Simulation ◽  
Simulation Method ◽  
Spur Gear ◽  
Cold Forging ◽  
Forming Process ◽  
Cold Forming ◽  
Forging Process ◽  
Flow Method ◽  
Precision Forging ◽  
Cold Precision Forging

The cold forging process of large module spur gear with four modules and 59mm breadth is performed by means of numerical simulation method. Two processes to forming such spur gears were compared by the simulation method, one is with the closed-die performing and extrusion in the finish-forging, the other is with divided-flow method in the finish-forging. Especially, the divided-flow method is analyzed in detail. The necessary reference and basis to realize practical cold precision forging process of spur gear with large modulus is provided eventually.

Intermediate Slabs and Optimization in Forging Process of Balance Elbow by FEM

2014 ◽  
Vol 721 ◽  
pp. 127-130
Author(s):  
Bo Jun Xiong ◽  
Ke Lu Wang ◽  
Jun Fang ◽  
Yun Huang
Keyword(s):  
Temperature Distribution ◽  
Strain Distribution ◽  
Simulation Analysis ◽  
Effective Strain ◽  
Maximum Load ◽  
Load Force ◽  
Fe Model ◽  
Forming Process ◽  
Rigid Plastic ◽  
Forging Process

Based on Deform-3D software, a 3D rigid-plastic FE model of forging forming process was established, then simulation analysis effective strain distribution, temperature distribution and load-stroke curve of three kinds of intermediate slabs (S1,S2,S3) in forging process. The results show that the optimized intermediate slab (S3) of effective strain distribution and temperature distribution is most homogeneous. And the maximum load force is minimum, the Shapes and dimensions of forging reach the preset value.

Development of Process Optimization for an Intelligent Knowledge-Based System for Spur Gear Precision Forging Die Design

2004 ◽  
Author(s):  
El-Sayed Aziz ◽  
C. Chassapis
Keyword(s):  
Parametric Design ◽  
Metal Flow ◽  
Optimization Method ◽  
Spur Gear ◽  
Die Design ◽  
Design System ◽  
Process Conditions ◽  
System Utilization ◽  
Forging Process ◽  
Precision Forging

Forging sequence design is mainly carried out using empirical rules for the design of the intermediate die shapes, in addition to many trail-and-error runs resulting in prolonged development times and higher costs. An integrated optimal design of preform shapes and process conditions approach to minimize the energy required is essential. The research presented in this article aims at developing an optimization algorithm to determine the optimum intermediate die shape-designs that minimize the total energy required during the forging process sequence. It is based on the results obtained in the previous research with focus on knowledge base and database representation to design precision forging solid gears and provide detailed process specification. A three-step algorithm, which addresses gear construction design, manufacturability analysis of gear construction and die-design optimization, is used to generate the parametric gear model and automatically extract design information for manufacturing process planning based on the feature-based parametric design system. Utilization of the shape optimization method for preform stages avoids costly production problems. The optimized approach provides accurate description of all stages involved in the forging process. Forging load and energy required, along with metal flow and detailed geometry specification of die forms for every forging stage are obtained. The forging energy requirements based on this approach are as much as 25% lower than those arrived from die designs based on actual tooth profile geometry.

A Single Stage Hot Forging Process of Alternator Poles

2011 ◽  
Vol 189-193 ◽  
pp. 2792-2795
Author(s):  
Cheng Yang ◽  
Sheng Dun Zhao ◽  
Jian Jun Zhang
Keyword(s):  
Hot Forging ◽  
Single Stage ◽  
Rigid Plastic ◽  
Forging Process ◽  
Precision Forging ◽  
Fem Method ◽  
Alternator Poles ◽  
Hot Forging Process ◽  
Deform 3D

Based on precision forging method, a single stage hot forging process of alternator poles is put forword, which the heated blank can be forging by only one press in a special closed die. In the last this process is verified by the software of Deform-3D which is employed rigid-plastic FEM method.

Finite Element Analysis for Precision Forging Process of United Transfer Driven Parking Gear

2007 ◽  
Vol 544-545 ◽  
pp. 327-330
Author(s):  
Geun An Lee ◽  
Seong Joo Lim ◽  
Dong Jin Kim ◽  
Yong Bok Park
Keyword(s):  
Finite Element ◽  
Metal Forming ◽  
Rigid Plastic ◽  
Element Analysis ◽  
3 Dimensional ◽  
Forging Process ◽  
Precision Forging ◽  
Strain Stress ◽  
3D Computer Simulation ◽  
Deform 3D

Forging process is one of the most basic metal forming processes. In this study a new forging process is applied to fabricate a precision forging product uniting parking and driven gears in order to obtain lightweight and cost effectiveness of an automobile. Since the united product using the precision forging process needs high quality and new manufacturing process, 3D computer simulation by FEM has been used to reduce some trial and errors in experiment and obtain the deformation, strain, stress and load of the workpiece and die. The study has tried to find out an optimal process including preform design putting emphasis on tooth filling by DEFORM-3D, a 3-dimensional rigid-plastic finite element code.

Sign in / Sign up

Export Citation Format

Share Document