Numerical Simulation for Cold Extrusion of Bevel Gear

2012 ◽  
Vol 497 ◽  
pp. 356-364
Author(s):  
Qing Hua Yang ◽  
Jun Pan ◽  
Jun Xiong Zhang ◽  
Wen Biao Chen ◽  
Bin Meng
Keyword(s):  
Numerical Simulation ◽  
Temperature Field ◽  
Bevel Gear ◽  
Basic Knowledge ◽  
Cold Extrusion ◽  
Forming Process ◽  
Load Curve ◽  
Extrusion Forming ◽  
3D Software ◽  
Deform 3D

A three-layers assembled cavity die and its technological measures were designed for cold extrusion forming for the bevel gear. Numerical simulation of the cold extrusion forming process was applied using Deform-3D software, load curve, velocity field, stress field and temperature field were analyzed, thus obtain the basic knowledge of the law of the bevel gear deformation. Subsequent targets for optimization were introduced, aiming to solve the remaining problems of the current cold extrusion forming. The accomplished work shows some significance in guiding how to design a die and its technological measures.

Numerical Simulation and Parameter Optimization of Cam’s Fine Blanking Process

2011 ◽  
Vol 396-398 ◽  
pp. 134-139
Author(s):  
An Long ◽  
Rui Ge ◽  
Yi Sheng Zhang ◽  
Li Bo Pan
Keyword(s):  
Numerical Simulation ◽  
Simulation Model ◽  
Parameter Optimization ◽  
Processing Parameters ◽  
Forming Process ◽  
Fine Blanking ◽  
3D Software ◽  
Blanking Process ◽  
Deform 3D

To conclude the mechanics of fine blanking, the numerical simulation model of a cam’s fine blanking process was established, the forming process was simulated by DEFORM-3D software, the deform principle was summarized. Then the effect of three key processing parameters such as gap between punch and die, pressure-pad-force/counter force, serrated ring postion to fine blanking quality were researched, optimized parameters in fine blanking were gained.

Investigation on Free-Wheel Hub for Starter Rotary Forming Process and Die Design Based on Numerical Simulation

2012 ◽  
Vol 557-559 ◽  
pp. 2155-2158
Author(s):  
Ping Wang ◽  
Liang Li
Keyword(s):  
Numerical Simulation ◽  
Hydraulic Press ◽  
Die Design ◽  
Quality Requirement ◽  
Forming Process ◽  
Forming Technology ◽  
Die Structure ◽  
Similar Part ◽  
3D Software ◽  
Deform 3D

Free-wheel hub plays an important role in automobile starter system, so there is higher quality requirement on geometry and precision. In order to improve the efficiency and comprehensive functions of the part, according to the features of the lower part with involute small module internal helical spline, the rotary forming technology was put forward, and the forming process was simulated by the DEFORM-3D software. In the die design, the use of rotary punch made the process of rotary forming achieved in common hydraulic press, and can serve as an important reference to the design of forming process and die structure of similar part.

Numerical Simulation Optimization Research of Cold Extrusion Forming for Injection Head

2013 ◽  
Vol 706-708 ◽  
pp. 444-447
Author(s):  
Qing Qing Lv ◽  
Li Quan Yang ◽  
Xiu Ting Lv ◽  
Lei Zhao ◽  
Xi Kui Wang
Keyword(s):  
Numerical Simulation ◽  
Treatment Process ◽  
Cold Extrusion ◽  
Finite Element Models ◽  
Forming Process ◽  
Backward Extrusion ◽  
Forward Extrusion ◽  
Forming Technology ◽  
Pre Treatment ◽  
Extrusion Forming

In order to obtain high-quality injection head, cold extrusion forming is adopted. Based on the study of forming technology for the injection head, reasonable process flow, cold extrusion pre-treatment process and boundary conditions are designed. Two finite element models in forward extrusion and backward extrusion forming ways are established. Taking DEFORM as the platform, the numerical simulation of forming process is carried out. Through simulation, the distribution of strain field, stress field and velocity field in the process of cold extrusion forming is preliminarily forecast, the merits and defects of two kinds of forming processes and the force state of mold are compared , the optimal forming scheme is determined.

Simulation Research on Ploughing Extrusion Angle Influence on Machinability

2020 ◽  
Vol 980 ◽  
pp. 117-125
Author(s):  
Ming Li ◽  
Rui Fan ◽  
Li Bao ◽  
Xue Yuan Zhang ◽  
Hong Yan Wang ◽  
...  
Keyword(s):  
Copper Plate ◽  
Cutting Performance ◽  
Virtual Design ◽  
Forming Process ◽  
Simulation Research ◽  
Groove Structure ◽  
Extrusion Forming ◽  
3D Software ◽  
Design And Manufacture ◽  
Deform 3D

In order to research the ploughing extrusion angle influence on cutting performance and realize the virtual design and manufacture of ploughing-extrusion forming cutter, the plough-extrusion forming process of wick micro-groove structure was simulated by DEFORM-3D software. The micro-copper tube with diameter of 6 mm was simplified to 0.4 mm thick copper plate in this paper. In the simulation process, only the single parameter of tool extrusion angle was changed (45°, 60°, and 90°). The structure, stress and strain distributions of copper plate fins formed by three kinds of extrusion angle cutters were analyzed. It is concluded that the plough-extrusion cutting performance of 60 degree extrusion angle cutter is the best.

An Analysis of the Effect of Feedstock on Continuous Extrusion Forming Process

2011 ◽  
Vol 127 ◽  
pp. 506-510 ◽  
Author(s):  
Li Chen ◽  
Bao Yun Song ◽  
Yuan Wen Liu
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Industrial Application ◽  
Forming Process ◽  
Copper Strip ◽  
Rotating Speed ◽  
Continuous Extrusion ◽  
Extrusion Forming ◽  
3D Software ◽  
Deform 3D

Continuous extrusion is an advanced process for manufacturing copper strip. Its successfully industrial application is to manufacture copper strip. Based on finite element method (FEM), using the Deform-3D software, this paper simulates continuous extrusion forming process for copper strip, and analyzes the effect of different feedstock diameter on metal flowing temperature, effective stress, velocity, rotating torque. The results show that: feedstock diameter greatly affects the continuous extrusion forming process; Under the same rotating speed, as feedstock diameter increases, the metal flowing velocity increases. It is benefit to enhance the productivity; As feedstock diameter increases, the temperature of the billet and tooling increases, and the torque of extrusion wheel increases, which leads to tooling wear seriously.

Analysis on Temperature Field of Work-Piece during Cross Wedge Rolling

2011 ◽  
Vol 230-232 ◽  
pp. 352-356
Author(s):  
Wen Ke Liu ◽  
Kang Sheng Zhang ◽  
Zheng Huan Hu
Keyword(s):  
Finite Element ◽  
Temperature Field ◽  
Metal Flow ◽  
Work Piece ◽  
Contact Deformation ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
Rigid Plastic ◽  
Finite Element Software ◽  
Deform 3D

Based on the rigid-plastic deformation finite element method and the heat transfer theories, the forming process of cross wedge rolling was simulated with the finite element software DEFORM-3D. The temperature field of the rolled piece during the forming process was analyzed. The results show that the temperature gradient in the outer of the work-piece is sometimes very large and temperature near the contact deformation zone is the lowest while temperature near the center of the rolled-piece keeps relatively stable and even rises slightly. Research results provide a basis for further study on metal flow and accurate shaping of work-piece during cross wedge rolling.

Influence of Heating Models on Necking Deformation during Tube Extrusion Process

2011 ◽  
Vol 189-193 ◽  
pp. 1778-1781 ◽  
Author(s):  
Gui Hua Liu ◽  
Yong Qiang Guo ◽  
Zhi Jiang
Keyword(s):  
Temperature Gradient ◽  
Material Flow ◽  
Extrusion Process ◽  
Work Piece ◽  
Tube Extrusion ◽  
Deformation Parameters ◽  
Flow Features ◽  
Extrusion Forming ◽  
3D Software ◽  
Deform 3D

By using Deform-3D software, the necking extrusion forming processes of integer trailer axle with two different heating means which are Uniform Heating (UH) method and Partly Heating (PH) method with temperature gradient are simulated. The influence of deformation parameters such as friction factor, necking coefficient, different temperature distribution of work-piece on the material flow features, stress and strain field, loading force and deformation process are analyzed in detail. According to the numerical simulation results, using PH method with temperature gradient can improve necking deformation during tube extrusion process.

scholarly journals Numerical Simulation and Process Optimization of Internal Thread Cold Extrusion Process

Materials ◽  
2020 ◽  
Vol 13 (18) ◽  
pp. 3960
Author(s):  
Hong-Ling Hou ◽  
Guang-Peng Zhang ◽  
Chen Xin ◽  
Yong-Qiang Zhao
Keyword(s):  
Numerical Simulation ◽  
Process Parameters ◽  
Orthogonal Experiment ◽  
Extrusion Process ◽  
Extrusion Temperature ◽  
Maximum Temperature ◽  
Cold Extrusion ◽  
Internal Thread ◽  
Bottom Hole ◽  
Extrusion Forming

In the internal thread extrusion forming, if the process parameters are not selected properly, the extrusion torque will increase, the extrusion temperature will be too high, or even the tap will break. In order to obtain effective process parameters under certain working conditions, this paper uses a combination of numerical simulation and process experiment to analyze the influence of the bottom hole diameter, extrusion speed, and friction factor on the extrusion torque and extrusion temperature. Through an orthogonal experiment, the significant influence law of different process parameters on the extrusion torque and extrusion temperature was studied, and the order of their influence was determined. Based on the optimal process parameters, numerical simulations and process tests were carried out, and the extrusion effect and related parameters were compared and analyzed. The results show that the extruded thread has clear contour, uniform tooth pitch, complete tooth shape, and good flatness. Compared with before optimization, the maximum extrusion torque has been reduced by 37.15%, the maximum temperature has been reduced by 29.72%, and the extrusion quality has been improved. It shows that the optimized method and optimized process parameters have good engineering practicability.

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.

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