On Numerical Simulations of the Micro-Gears and their Cold Forging Process

2009 ◽  
Vol 419-420 ◽  
pp. 17-20
Author(s):  
Chin Yu Wang ◽  
Hsin Te Wang
Keyword(s):  
Spline Function ◽  
Simulation Software ◽  
Cold Forging ◽  
Design Parameters ◽  
Forging Process ◽  
Gear Design ◽  
Cubic Spline Function ◽  
Corner Filling ◽  
Gear Profile ◽  
Parametric Cubic Spline

In this paper, a parametric cubic spline function for generating gear profile is proposed. The spline function includes new gear design parameters such as pressure angle, number of teeth, module, and tooth tip circle modification. The proposed geometry can improve corner filling condition. Finally, the simulation software DEFORM is used to simulate the cold forging process of the micro-gears with different profiles.

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.

Development of New Method for Calculating Engaged Profiles of Gears

1989 ◽  
Author(s):  
D. Wang ◽  
Z. Qi ◽  
F.-C. T. Shiue
Keyword(s):  
Spline Function ◽  
Gear Tooth ◽  
Cutting Tools ◽  
Computational Procedure ◽  
Grinding Wheels ◽  
Curve Fit ◽  
Manufacturing Accuracy ◽  
Cubic Spline Function ◽  
Parametric Cubic Spline ◽  
General Method

Abstract In investigating the problems of engagement of different gear tooth profiles, the authors have found a generality for these problems. Meanwhile, according to the theory of computational geometry and numerical experiments, a parametric cubic spline function is found as a proper curve-fit technique to represent the tooth profiles of these gears. A general method and its numerical algorithm, based on the generality observed and the spline function chosen, is developed for the calculation of gear cutting tools and mating gears with arbitrary profiles. The cutting tools applied include: gear cutters, grinding wheels, and form milling cutters. The method can also be applied to the inspection of the manufacturing accuracy of the gear or helical screw profiles. A computational procedure is illustrated.

Servo Forging Technology and Mold Development of the Pulley of AISI-1010 Low Carbon Steel

2018 ◽  
Vol 917 ◽  
pp. 257-261
Author(s):  
Tung Sheng Yang ◽  
Chun Wang ◽  
Li Xiu Liu ◽  
Shuen Huei Yao
Keyword(s):  
Carbon Steel ◽  
Pulse Wave ◽  
Equivalent Stress ◽  
Low Carbon Steel ◽  
Simulation Software ◽  
Cold Forging ◽  
Low Carbon ◽  
Forming Force ◽  
Forging Process ◽  
Maximum Equivalent Stress

Aimed at AISI-1010 low carbon steel pulley components, a finite element method-based metal forming simulation software of DEFORM 3D was used to simulate and analyze the near net forging process for the low carbon steel pulley, and to design forging molds. This technology was used in the pulley tooth forging in conjunction with the servo press-based servo motion curve technology. First, the cold forging process of the pulley preform forging and the near net forging were simulated. Also, the applications of the pulse wave servo motion curve in the pulley tooth forging was simulated, which was compared with the traditional motion curve-based forging forming, where the comparisons focused on the maximum forming force and maximum equivalent stress. The results indicated that the maximum forming force and the maximum equivalent stress of the punch caused by the pulse wave servo motion curve was smaller than caused by the traditional motion curve.

scholarly journals Quality Evaluation of Cold Embossed Hole Based on Profile Measurement Technique

2012 ◽  
Vol 626 ◽  
pp. 564-568
Author(s):  
A.B. Abdullah ◽  
S.M. Sapuan ◽  
Z. Samad ◽  
N.A. Aziz
Keyword(s):  
Aluminum Alloy ◽  
Measurement Technique ◽  
Quality Evaluation ◽  
Surface Measurement ◽  
Cold Forging ◽  
Design Parameters ◽  
Profile Measurement ◽  
Forging Process ◽  
Experimental Rig

The main objective of this study is to assess the quality of the cold forging hole by focusing the roundness of the hole. In this study, a cold forging process of blind hole of Aluminum Alloy AA6061 experimental rig was developed. In the experiment, two major design parameters i.e. the depth of embossing and diameter of the punch were studied and their influence to the roundness was measured based on the profile obtained from the surface measurement technique. The results will be validated using commercial roundtest machine.

scholarly journals Application of Numerical Simulation and Physical Modeling for Verifying a Cold Forging Process for Rotary Sleeves

2021 ◽  
Author(s):  
Tomasz Bulzak ◽  
Grzegorz Winiarski ◽  
Łukasz Wójcik ◽  
Mirosław Szala
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Experimental Tests ◽  
Simulation Software ◽  
Cold Forging ◽  
Work Piece ◽  
Geometrical Parameters ◽  
Forging Process ◽  
Forged Parts ◽  
Element Method

AbstractThis paper presents the modeling of a cold forging process for a rotary sleeve. The process of forging a EN 42CrMo4 steel part was first modeled numerically by the finite element method using simulation software DEFORM 3D ver. 11.0. After that, the developed forging process was verified by experimental tests carried out in laboratory conditions with the use of 1:2 scale tools and a material model of aluminum alloy EN AW-6060. Finite element method (FEM) results demonstrated that rotary sleeves could be formed from tubes by cold forging. Results of the experimental tests showed, however, that the material inside the hole of the work piece might not adhere to the surface of the sizing pin. Distributions of strain and stress during the forging process are determined. Geometrical parameters of forged parts obtained in experimental tests are compliant with the dimensions of forged parts simulated by FEM. In addition, experimental forces of the forging process show a high agreement with the forces obtained in FEM simulations.

scholarly journals Numerical Method for Solving Nonlinear Equations Arising in Astrophysics

2019 ◽  
Vol 8 (4) ◽  
pp. 1075-1078
Keyword(s):  
Singular Point ◽  
Spline Function ◽  
Linear Problem ◽  
Cubic Spline ◽  
Linear Problems ◽  
Isothermal Gas ◽  
Cubic Spline Function ◽  
Mathematica Software ◽  
The Given ◽  
Parametric Cubic Spline

In this paper, a parametric cubic spline function was used to get the solution of a non-linear problem for an isothermal gas sphere. The quasi-linearization procedure was used to reduce the given problem to a sequence of linear problems, the resulting equations are modified at the singular point and are handled by using parametric cubic spline for determining the numerical results. All computations have been carried out by the Mathematica software program package. The findings of computational outcomes on those astrophysics problems confirmed that the technique is legitimate for the solution of these kinds of equations.

Effect of design parameters on stresses occurring at the tooth root in a spur gear pressed on a shaft

2021 ◽  
pp. 095440892199529
Author(s):  
Fatih Güven
Keyword(s):  
Internal Pressure ◽  
Tangential Stress ◽  
Spur Gear ◽  
Design Parameters ◽  
Interference Fit ◽  
Gear Design ◽  
Compact Design ◽  
Fit Tolerance ◽  
Moderate Stress ◽  
Good Agreement

Gears are commonly used in transmission systems to adjust velocity and torque. An integral gear or an interference fit could be used in a gearbox. Integral gears are mostly preferred as driving gear for a compact design to reduce the weight of the system. Interference fit makes the replacement of damaged gear possible and re-use of the shaft compared to the integral shaft. However, internal pressure occurs between mating surfaces of the components mated. This internal pressure affects the stress distribution at the root and bottom land of the gear. In this case, gear parameters should be re-considered to assure gear life while reducing the size of the gear. In this study, interference fitted gear-shaft assembly was examined numerically. The effects of rim thickness, profile shifting, module and fit tolerance on bending stress occurring at the root of the gear were investigated to optimize gear design parameters. Finite element models were in good agreement with analytical solutions. Results showed that the rim thickness of the gear is the main parameter in terms of tangential stress occurring at the bottom land of the gear. Positive profile shifting reduces the tangential stress while the pitch diameter of the gear remains constant. Also, lower tolerance class could be selected to moderate stress for small rim thickness.

Some investigations on punch force in cold forging process by FE simulation

2021 ◽  
Author(s):  
Praveenkumar M. Petkar ◽  
V. N. Gaitonde ◽  
T. K. G. Raju
Keyword(s):  
Fe Simulation ◽  
Cold Forging ◽  
Punch Force ◽  
Forging Process

scholarly journals Multi-Stage Cold Forging Process for Manufacturing a High-Strength One-Body Input Shaft

Materials ◽  
2021 ◽  
Vol 14 (3) ◽  
pp. 532
Author(s):  
A Jo ◽  
Myeong Jeong ◽  
Sang Lee ◽  
Young Moon ◽  
Sun Hwang
Keyword(s):  
High Strength ◽  
Microstructural Characterization ◽  
Fatigue Tests ◽  
Machining Process ◽  
Cold Forging ◽  
Element Analysis ◽  
Forging Process ◽  
Input Shaft ◽  
Multi Stage ◽  
The One

A multi-stage cold forging process was developed and complemented with finite element analysis (FEA) to manufacture a high-strength one-body input shaft with a long length body and no separate parts. FEA showed that the one-body input shaft was manufactured without any defects or fractures. Experiments, such as tensile, hardness, torsion, and fatigue tests, and microstructural characterization, were performed to compare the properties of the input shaft produced by the proposed method with those produced using the machining process. The ultimate tensile strength showed a 50% increase and the torque showed a 100 Nm increase, confirming that the input shaft manufactured using the proposed process is superior to that processed using the machining process. Thus, this study provides a proof-of-concept for the design and development of a multi-stage cold forging process to manufacture a one-body input shaft with improved mechanical properties and material recovery rate.

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