Numerical Simulation and Die Design for Vibration Extrusion of Spur Gear

2012 ◽  
Vol 580 ◽  
pp. 37-41
Author(s):  
Qiong Lin ◽  
Bin Meng ◽  
Qing Hua Yang
Keyword(s):  
Numerical Simulation ◽  
Flow Characteristic ◽  
Metal Flow ◽  
Spur Gear ◽  
Extrusion Process ◽  
Die Design ◽  
Forming Process ◽  
Extrusion Die ◽  
Die Structure ◽  
Metal Extrusion

The numerical simulation for spur gear vibration extrusion is performed in this paper. The metal flow characteristic and load-stroke relationship during forming process is analyzed and then compared with traditional metal extrusion process. The results revealed the axial vibration of cavity die can both reduce forming load and benefit for metal flow, which could achieve better forming quality. Finally according to the processing requirements, the vibration generator and whole extrusion die structure is designed.

Comparison of Metal Flow Characteristics in Aluminium Extrusion Die using Numerical Simulations for AA6063 and AA7075

2021 ◽  
Vol 13 (2) ◽  
Author(s):  
V.N.S.U. Viswanath Ammu ◽  
Samrat Ambade ◽  
N.S. Anas ◽  
R.N. Chouhan ◽  
Anupam Agnihotri
Keyword(s):  
Numerical Simulation ◽  
Metal Flow ◽  
Flow Characteristics ◽  
Die Design ◽  
Maximum Speed ◽  
Simulation Studies ◽  
Industrial Sectors ◽  
Extrusion Die ◽  
Aluminium Extrusion ◽  
Alloy Properties

Aluminium extruded profiles are used for light weight structures used in architecture, transportation, aerospace, industrial sectors etc. Increasing use of profiles for applications has been driving extruiders to focus on reliable techniques to produce profile that meet consistent quality. In aluminium extrusion, profitability can be achieved by pushing maximum number of billets i.e maximum speed during production. However, in the shopfloor different aluminium alloys and geometries are limited by manufacturibility limitations which based on alloy properties and metal flow charcateritics. Hence, product quality is largely dependant on the closer control of metal flow charcateritics that can be compensated by right quality aluminium billet and die design paramaters. In this regard, numerical simulation studies have been adopted prior to production to ensure the consistent and reliable quality of profiles. In this technical communication, metal flow characteristics such as velocity, temperature and strain rate in an extrusion die were compared using numerical simulation studies for two alloys namely AA6063 and AA7075.

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 and Process Test for Cold Extrusion of Wheel Hub Bearing Rings

2010 ◽  
Vol 97-101 ◽  
pp. 100-106
Author(s):  
Bin Meng ◽  
Hai Wei Wu ◽  
Guan Jun Bao ◽  
Hui Li ◽  
Qing Hua Yang
Keyword(s):  
Numerical Simulation ◽  
Metal Flow ◽  
Flow Characteristics ◽  
Element Model ◽  
Extrusion Process ◽  
Die Design ◽  
Cold Extrusion ◽  
Rigid Plastic ◽  
Process Specification ◽  
Bearing Rings

This paper describes procedures and results obtained using 3D rigid plastic thermal-mechanical finite element model of wheel hub bearing rings. Numerical simulation for cold extrusion process is performed and metal flow characteristics, distribution of effective stress & temperature field and load-stroke curve are analyzed. Approach of tool wear prediction is also explored using Archard model . Process test revealed that numerical simulation provides theory basis and useful guidance for cold extrusion process specification and die design.

Forming Process Numerical Simulation of Beverage Can

2013 ◽  
Vol 753-755 ◽  
pp. 928-931 ◽  
Author(s):  
Guo Qiang Zhang ◽  
Ji Qiang Zhai ◽  
Ting Hao ◽  
Wen Juan Wang ◽  
Xu Biao Yang ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Production Process ◽  
Process Parameters ◽  
Forming Process ◽  
Development Costs ◽  
Die Structure ◽  
Computer Aided ◽  
The Cost ◽  
Manufacturing Time ◽  
Process Method

Numerical simulation in the 200ml beverage can forming process was carried out by means of computer aided engineering. Beverage can drawing production process parameters and a forecast for the production process of all sorts of possible defects were obtained. Based on the results of the simulation, we can improve die structure and process method. Thus the development costs of die will be reduced. The manufacturing time of die will be shortened. The purpose of reducing the cost of production can be achieved ultimately.

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.

Effects of Welding Chamber Step on Extrusion Process of a Complex Hollow Profile

2010 ◽  
Vol 148-149 ◽  
pp. 1684-1688 ◽  
Author(s):  
Hao Chen ◽  
Guo Qun Zhao ◽  
Cun Sheng Zhang ◽  
Jiang Wei Liu
Keyword(s):  
Quality Control ◽  
Numerical Model ◽  
Product Quality ◽  
Cross Section ◽  
Metal Flow ◽  
Extrusion Process ◽  
Weld Quality ◽  
Extrusion Die ◽  
Temperature Distributions ◽  
Welding Pressure

The extrusion die is of great importance in the quality control of profile production. Yet in practice, the design of extrusion die is mainly dependent on the experience and intuition of die designers, which is difficult to guarantee product quality and productivity. In this paper, a numerical model was developed based on HyperXtrude with an attempt to investigate the effects of the shape of the welding chamber on metal flow and weld quality. The porthole dies with different steps of welding chamber were designed and applied to extrude an identical profile. Numerical results showed that with an increasing step of welding chamber, more uniform velocity and temperature distributions in the cross-section of the extrudate were observed. In addition, the weld quality was improved owing to increasing welding pressure, when adopting the multi-step welding chamber.

Numerical and Experimental Studies on Extrusion of Fan-Shaped Shell of Magnesium Alloy

2012 ◽  
Vol 626 ◽  
pp. 381-385
Author(s):  
Bao Hong Zhang ◽  
Yao Jin Wu ◽  
Zhi Min Zhang
Keyword(s):  
Numerical Simulation ◽  
Magnesium Alloy ◽  
Experimental Studies ◽  
Extrusion Process ◽  
Base Thickness ◽  
Forming Process ◽  
Backward Extrusion ◽  
Minimal Base ◽  
Billet Shape

This paper presents a case study of optimizing the forming process for a fan-shaped shell component. Numerical simulation was used to study the backward extrusion process of a fan-shaped shell. The underfill defect produced at the opening of the extruded shell due to the billet shape was solved and the minimal base thickness required to avoid the presence of the underfill defect at the bottom corner of the component was defined through the numerical simulation. The extrusion drawing and forming process of the fan-shaped shell were designed on the basis of the results of the numerical simulation. Forming experiments had been performed on the fan-shaped shell at 380 °C and cracking was found on the outside wall in the center of the extruded shell. Choked groove on the inner wall of the die and reducing the lubrication had been used to avoid the presence of cracking. The fan-shaped shell of AZ31 magnesium alloy has been successfully formed by the three-stage forming process of hot upsetting, hot backward extrusion and cold sizing.

Influence of Friction on Metal Flow Behaviour and Die Stress of Backward Extrusion

2011 ◽  
Vol 117-119 ◽  
pp. 1719-1722
Author(s):  
Yong Shun Yang ◽  
Tian Tian Yin ◽  
Ke Feng
Keyword(s):  
Numerical Simulation ◽  
Metal Flow ◽  
Extrusion Process ◽  
Flow Behaviour ◽  
Backward Extrusion ◽  
Die Stress ◽  
3D Software ◽  
Deformation Area ◽  
Deform 3D ◽  
Unit Pressure

In the paper, the Deform-3D software was used to simulate the mechanism of metal flow behaviour under the influence of different friction in the backward extrusion process, and further study its influence on die stress. The numerical simulation demonstrates that: smaller friction could reduce difficult deformation area of extrusion metal significantly; friction state not only affected the plastic deformation extent, but also would increase the consumption of extrusion energy; the unit pressure of punch and stress of inner wall increased along with the increase of friction, meanwhile, the ratio of them increased as well.

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