A Study of the Effects of Reversal Cycles in the Gear Rolling Process by Using Finite Element Simulations

The manufacturing of machine components with sustainable and innovative methods is an interesting topic for research. Gears are some components which have complexity in both design and production technology. Therefore applying innovative methods on gear manufacturing can be of interest to industry. One of the most promising production methods for gear wheels is Gear Rolling. The gear wheel is formed during a certain rolling process from a cylindrical blank into the final designed shape. The process of gear rolling with rotational gears is progressing by running several rolling cycles with one, or two dies in contact with a work-piece. A specified rotational speed and radial feed speed is applied to the dies in order to form the required geometry on the blank. In this paper, the authors have simulated the process with the finite element code, DEFORM 3D. Especially the effects of reversal cycles on final gear wheel geometry have been evaluated from the simulations. Different settings for the rotation direction of the dies have been used and the effects are evaluated with specific quality criteria.

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Finite Element Simulation as a Tool to Evaluate Gear Quality after Gear Rolling

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.554-557.300 ◽

2013 ◽

Vol 554-557 ◽

pp. 300-306 ◽

Cited By ~ 3

Author(s):

Alireza Khodaee ◽

Arne Melander

Keyword(s):

Finite Element ◽

Finite Element Simulation ◽

Gear Wheel ◽

Spur Gear ◽

Interesting Case ◽

Shape Accuracy ◽

Good Surface ◽

Element Simulation ◽

Gear Wheels ◽

Gear Rolling

Gear rolling is a manufacturing technique for gears with many advantages like reduced material consumption, reduced scrap generation, fast cycle times, good surface quality and improved final properties of the gear wheels compared to conventional production technology based on machining. In order to make use of all these advantages it is desired to reach the final shape of the gear wheel already after rolling. This means that post treatments like grinding should be avoided. This puts high requirements on the shape accuracy after gear rolling. In this paper it was studied if finite element simulation could be used to evaluate the shape accuracy after gear rolling. The measurement of shape accuracy of gear wheels is specified in standards like ISO1328-1. The allowed deviations from nominal shape are often of the order of 10-30 μm for very good qualities. So if such evaluation shall be possible from a finite element simulation the accuracy must be of the same order. In order to have sufficient accuracy of the finite element simulation 2D simulations were performed on a spur gear. The FE code DEFORM was utilized. The shape accuracy was evaluated for gear rolling of two cases. One case had gears with the module of 1 mm. The other case involved gears with a significantly larger module of 4 mm. This was an interesting case since it is known that it is more difficult to roll the gear with good accuracy in large modules.

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Investigation on Constant and Variable Feed Speeds Effects in Ring Rolling Process Using 3D FEM

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.264-265.1776 ◽

2011 ◽

Vol 264-265 ◽

pp. 1776-1781 ◽

Cited By ~ 1

Author(s):

Nassir Anjami ◽

Ali Basti

Keyword(s):

Finite Element ◽

Rolling Process ◽

Ring Rolling ◽

Outer Diameter ◽

Fe Model ◽

Feed Speed ◽

3D Fem ◽

Cold Ring Rolling ◽

Plastic Deformation Behavior ◽

Ring Rolling Process

Although cold ring rolling (CRR) process is largely used in the manufacturing of profiled rings like bearing races, research on this purpose has been scant. In this study, based on a validated finite element (FE) model, CRR process is simulated regarding the variable and constant feed speeds of the mandrel roll which lead to constant and variable values of the ring's diameter growth rates respectively using a 3D rigid-plastic finite element method (FEM). Major technological problems involved in the process including plastic deformation behavior, strain distribution and its uniformity, Cockcroft and Latham damage field and final outer diameter of ring are fully investigated. The results of simulations would provide a good basis for process control especially feed speed controlled mills and guiding the design and optimization of both cold and hot ring rolling process.

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Process Planning of Gear Rolling with the Finite Element Method

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.622-623.986 ◽

2014 ◽

Vol 622-623 ◽

pp. 986-992 ◽

Cited By ~ 1

Author(s):

Alireza Khodaee ◽

Arne Melander

Keyword(s):

Gear Wheel ◽

Rolling Process ◽

Load Level ◽

Axial Loads ◽

Fe Method ◽

Plastic Deformation Process ◽

Gear Manufacturing ◽

Rolling Method ◽

Gear Wheels ◽

Gear Rolling

Gear rolling is a new gear manufacturing process which can partly replace traditional gear milling processes. High gear wheels with modules of 4mm up to 6mm are of interest to truck manufacturing. The process is of interest since it involves no material removal and since it has the potential to give good performance of the gear wheels. The process must be adopted for the large plastic deformations which occur for gear rolling with large modules. In this paper special emphasis will be put to loads and torques during the gear rolling process of gear wheels with large modulus. The FE method will be used to model the plastic deformation process to fully form a gear wheel with the gear rolling method. The radial and axial loads and the torques in this process are predicted. The loads of the process are high compared to the situation for small gear wheels so simulation of load level is essential for the design of rolling machines for high gears.

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Finite element simulation of PM gear rolling process

Powder Metallurgy ◽

10.1179/1743290115y.0000000011 ◽

2015 ◽

Vol 58 (3) ◽

pp. 202-208 ◽

Cited By ~ 1

Author(s):

H. Cho ◽

Y. Shin ◽

S. W. Hwang ◽

J. H. Gu ◽

J. H. Baek ◽

...

Keyword(s):

Finite Element ◽

Finite Element Simulation ◽

Rolling Process ◽

Element Simulation ◽

Gear Rolling

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Forming Interrogation of Rolling Process using Rollers

International Journal of Innovative Technology and Exploring Engineering - Special Issue ◽

10.35940/ijitee.k1070.09811s219 ◽

2019 ◽

Vol 8 (11S2) ◽

pp. 437-441

Keyword(s):

Finite Element ◽

3D Model ◽

Three Dimensional ◽

Rolling Process ◽

Work Piece ◽

Slab Thickness ◽

Dimensional Model ◽

Three Dimensional Model ◽

Element Analysis ◽

Reinforced Plastic

In this article to be created three dimensional model of reinforced plastic using finite element analysis (FEA) to simulated slab rolling between rollers by wide thickness in work piece is analyzed. The behaviour of materials while rolling roller at the time of pass, finite element deform3d program employed and developed 3D model of the heat developed rolling process. The influences of different process parameters namely speed of the roller, thickness of the slab, thickness reduction & heat transfer coefficient are taken an account. The stress, strain & strain rate, the temperature distribution in the roll and the slab, are developed throughout a steady-state analysis of the process involved. From the simulation process, the machining possibilities are obtained

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Experiment and Finite Element Analysis Research on Surface Roughness in Micro-Grinding H62

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.1136.21 ◽

2016 ◽

Vol 1136 ◽

pp. 21-29

Author(s):

Xue Long Wen ◽

Ya Dong Gong ◽

Yao Sun ◽

Jun Cheng ◽

De Chun Ba

Keyword(s):

Finite Element Analysis ◽

Surface Roughness ◽

Finite Element ◽

Surface Quality ◽

Influence Factors ◽

Work Piece ◽

Feed Speed ◽

Element Analysis ◽

Important Processing ◽

Grinding Tool

Micro-grinding is an important processing method in micro-manufacturing field. The influence factors of surface quality in micro-grinding are discussed in the article. The models of finite element analysis (FEA) in micro-grinding H62 with electroplated CBN micro-grinding tool were established. The influence of different grinding factors on the surface quality of the work-piece was discussed by FEA. Different grains sizes were considered to reveal the influence rules on surface roughness in grinding experiments. The results show that the surface roughness decreases with the decreasing of the feed speed and the increasing of the grinding speed. A better surface quality can be achieved with smaller grains sizes. The minimum surface roughness can reach 481nm in side grinding H62.

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Machine Learning-Based Models for the Estimation of the Energy Consumption in Metal Forming Processes

Metals ◽

10.3390/met11050833 ◽

2021 ◽

Vol 11 (5) ◽

pp. 833

Author(s):

Irene Mirandola ◽

Guido A. Berti ◽

Roberto Caracciolo ◽

Seungro Lee ◽

Naksoo Kim ◽

...

Keyword(s):

Machine Learning ◽

Finite Element ◽

Energy Consumption ◽

Metal Forming ◽

Mutual Influence ◽

Rolling Process ◽

Ring Rolling ◽

Gradient Boosting ◽

Average Error ◽

Ring Rolling Mill

This research provides an insight on the performances of machine learning (ML)-based algorithms for the estimation of the energy consumption in metal forming processes and is applied to the radial-axial ring rolling process. To define the mutual influence between ring geometry, process settings, and ring rolling mill geometries with the resulting energy consumption, measured in terms of the force integral over the processing time (FIOT), FEM simulations have been implemented in the commercial SW Simufact Forming 15. A total of 380 finite element simulations with rings ranging from 650 mm < DF < 2000 mm have been implemented and constitute the bulk of the training and validation datasets. Both finite element simulation settings (input), as well as the FI (output), have been utilized for the training of eight machine learning models, implemented with Python scripts. The results allow defining that the Gradient Boosting (GB) method is the most reliable for the FIOT prediction in forming processes, being its maximum and average errors equal to 9.03% and 3.18%, respectively. The trained ML models have been also applied to own and literature experimental cases, showing a maximum and average error equal to 8.00% and 5.70%, respectively, thus proving once again its reliability.

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Research on Process Parameter Optimization of the High-Neck Flange Closed Rolling Based on the Orthogonal Experimental Design

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.494-495.461 ◽

2014 ◽

Vol 494-495 ◽

pp. 461-465 ◽

Cited By ~ 1

Author(s):

Bao Shou Sun ◽

Zhe Hong ◽

Long Qing Xu ◽

Xue Dao Shu ◽

Bo Qin Gu ◽

...

Keyword(s):

Experimental Design ◽

Parameter Optimization ◽

Rotational Speed ◽

Rolling Process ◽

Process Parameter ◽

Orthogonal Experimental Design ◽

Feed Speed ◽

Initial Blank ◽

Two Factors ◽

Deform 3D

This paper simulates the process of the high-neck flange closed rolling on DEFORM-3D and optimizes the rolling process parameter by analyzing the results based on the orthogonal experimental design. For the high-neck flange, the results show that the effects on ellipticity are in the order of the mandrel feed speed, the main roll rotational speed and initial blank temperature. The former two factors show the significance while the initial blank temperature does not show that.

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

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.230-232.352 ◽

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.

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