FE-Based Design of a Forging Tool System for a Hybrid Bevel Gear

2017 ◽  
Vol 742 ◽  
pp. 544-551 ◽  
Author(s):  
Bernd Arno Behrens ◽  
Anas Bouguecha ◽  
Christian Bonk ◽  
Martin Bonhage ◽  
Anna Chugreeva ◽  
...  
Keyword(s):  
Material Flow ◽  
Complex Geometry ◽  
Bevel Gear ◽  
Forging Process ◽  
Material Characterisation ◽  
Forming Technology ◽  
Local Material ◽  
Process Route ◽  
Tailored Forming ◽  
Initial Results

Multi-material solutions offer numerous benefits producing tailored-made hybrid components with enhanced application-optimized properties contrary to conventional monolithic parts. However, designing of corresponding manufacturing processes is often challenging due to various technical aspects. This paper represents a process route for the manufacturing of a hybrid bevel gear by means of tailored forming technology with a focus on die forging and describes the main challenges within the forming stage. Due to local material-specific properties, uncommon material flow and complex geometry of the final part, an individual forming tool system with a geared die was accurately designed. Besides the forming tool system, the FE-based design of the forging process as well as the necessary material characterisation will be presented. Finally, the initial results of the experimental forging investigations are shown.

Current-Dependent Dynamics of Bidirectional Self-Folding for Multi-Layer Polymers Using Local Resistive Heating

2021 ◽  
Vol 143 (3) ◽  
Author(s):  
Moataz Elsisy ◽  
Evan Poska ◽  
Moataz Abdulhafez ◽  
Mostafa Bedewy
Keyword(s):  
Material Flow ◽  
Shape Memory Polymer ◽  
Three Dimensional ◽  
Element Model ◽  
Lightweight Structures ◽  
Local Material ◽  
Polymer Sheets ◽  
New Process ◽  
Origami Engineering

Abstract The purpose of this paper is to characterize the dynamics and direction of self-folding of pre-strained polystyrene (PSPS) and non-pre-strained styrene (NPS), which results from local shrinkage using a new process of directed self-folding of polymer sheets based on a resistively heated ribbon that is in contact with the sheets. A temperature gradient across the thickness of this shape memory polymer (SMP) sheet induces folding along the line of contact with the heating ribbon. Varying the electric current changes the degree of folding and the extent of local material flow. This method can be used to create practical three-dimensional (3D) structures. Sheets of PSPS and NPS were cut to 10 × 20 mm samples, and their folding angles were plotted with respect to time, as obtained from in situ videography. In addition, the use of polyimide tape (Kapton) was investigated for controlling the direction of self-folding. Results show that folding happens on the opposite side of the sample with respect to the tape, regardless of which side the heating ribbon is on, or whether gravity is opposing the folding direction. The results are quantitatively explained using a viscoelastic finite element model capable of describing bidirectional folds arising from the interplay between viscoelastic relaxation and strain mismatch between polystyrene and polyimide. Given the tunability of fold times and the extent of local material flow, resistive-heat-assisted folding is a promising approach for manufacturing complex 3D lightweight structures by origami engineering.

scholarly journals Well-posedness of a non-local model for material flow on conveyor belts

2020 ◽  
Vol 54 (2) ◽  
pp. 679-704 ◽  
Author(s):  
Elena Rossi ◽  
Jennifer Weißen ◽  
Paola Goatin ◽  
Simone Göttlich
Keyword(s):  
Material Flow ◽  
Numerical Study ◽  
Approximate Solutions ◽  
Approximation Schemes ◽  
Lipschitz Continuous ◽  
Flux Function ◽  
Local Material ◽  
Uniqueness Of The Solution ◽  
Non Local ◽  
Volume Approximation

In this paper, we focus on finite volume approximation schemes to solve a non-local material flow model in two space dimensions. Based on the numerical discretisation with dimensional splitting, we prove the convergence of the approximate solutions, where the main difficulty arises in the treatment of the discontinuity occurring in the flux function. In particular, we compare a Roe-type scheme to the well-established Lax–Friedrichs method and provide a numerical study highlighting the benefits of the Roe discretisation. Besides, we also prove the L1-Lipschitz continuous dependence on the initial datum, ensuring the uniqueness of the solution.

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.

Effect of Friction conditions on Material Flow in FE Analysis of Al Piston Forging Process

2019 ◽  
Vol 20 (10) ◽  
pp. 1643-1652 ◽  
Author(s):  
Seong-Won Lee ◽  
Jae-Wan Jo ◽  
Man-Soo Joun ◽  
Jung-Min Lee
Keyword(s):  
Material Flow ◽  
Fe Analysis ◽  
Forging Process

scholarly journals Preform Optimization for Bevel Gear of Warm Forging Process

Procedia CIRP ◽  
2018 ◽  
Vol 72 ◽  
pp. 340-345 ◽  
Author(s):  
Hong-Seok Park ◽  
Febriani Risky Ayu ◽  
Saurabh Kumar
Keyword(s):  
Bevel Gear ◽  
Forging Process ◽  
Preform Optimization ◽  
Warm Forging

FEM Analysis for Tangible Component Production

2014 ◽  
Vol 611-612 ◽  
pp. 1657-1664 ◽  
Author(s):  
Mario Rosso ◽  
Ildiko Peter
Keyword(s):  
Material Flow ◽  
Hot Forging ◽  
Fem Analysis ◽  
Forging Process ◽  
Die Life ◽  
One Step ◽  
Hot Forging Process

In high temperature metal forming techniques, analysis of the material flow and deformation as well as wear distribution during forging are very important, because they are directly correlated to the quality of the final component and to the productivity and die life. In this paper a commercially available Finite Element Method based simulator, namely Transvalor Forge 2008©, is used to numerically investigate on the effects of the various parameters on the mode of the failure of dies during hot forging. The exploration has the purpose to evaluate the possibility and related benefits of the advancement from a traditional hot forging process to a modern thixoforging one in the case study of steel-made steering pistons production. As a first step, the part related to the hot forging process is in detailed analyzed, in order to get an exhaustive description of the role of the different parameters. One step and two step solutions are proposed and discussed.

One Action Press Forming of Helix Bevel Gear by Using Multi-Cylinder Press and Die Heating System

2018 ◽  
Vol 12 (5) ◽  
pp. 767-774
Author(s):  
Katsuaki Nakamura ◽  
◽  
Hiroshi Koresawa ◽  
Hiroyuki Narahara
Keyword(s):  
Hot Forging ◽  
High Hardness ◽  
Heating System ◽  
Bevel Gear ◽  
Cold Forging ◽  
Machining Time ◽  
Forging Process ◽  
Forged Parts ◽  
Almost All ◽  
Forging Press

In the case of a complex shaped helix bevel gear, the forging of complete gear tips is very difficult to achieve. In almost all cases, tooth profile is finished by cutting machine from simple shaped forged parts, therefore requiring considerable machining time and cost. However, there are many approaches to forging. Forging is mainly classified as hot and cold forging, and uses a single motion press. In the case of hot forging takeoff of products from die is difficult by the cooling shrinkage from die and accuracy of products is lower level than cold forging. In addition, in the case of cold forging, a complicated shape is difficult to achieve based on the lack of ductility of the materials. To realize a helix bevel gear using a single forging operation, we applied a tool heating system and three-axis forging press. The tool heating system is applied to prevent a temperature decrease in the material by contact between the tool and forging material during the forging process. Further, to optimize the forging direction and timing, we used a three-axis forging press. We confirmed good forging capability of this special forging process, as well as the high precision of the forged parts. Moreover, through the thermo-mechanical control of steel and the tool temperature, the forged parts showed good mechanical properties, such as high hardness.

Multi-Input Multi-Output (MIMO) Modeling and Control for Stamping

2010 ◽  
Vol 132 (4) ◽  
Author(s):  
Yongseob Lim ◽  
Ravinder Venugopal ◽  
A. Galip Ulsoy
Keyword(s):  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Material Flow ◽  
Process Model ◽  
Complex Geometry ◽  
Flow Characteristics ◽  
Forming Process ◽  
Punch Force ◽  
Force System

The binder force in sheet metal forming controls the material flow into the die cavity. Maintaining precise material flow characteristics is crucial for producing a high-quality stamped part. Process control can be used to adjust the binder force based on tracking of a reference punch force trajectory to improve part quality and consistency. The purpose of this paper is to present a systematic approach to the design and implementation of a suitable multi-input multi-output (MIMO) process controller. An appropriate process model structure for the purpose of controller design for the sheet metal forming process is presented and the parameter estimation for this model is accomplished using system identification methods. This paper is based on original experiments performed with a new variable blank holder force (or variable binder force) system that includes 12 hydraulic actuators to control the binder force. Experimental results from a complex-geometry part show that the MIMO process controller designed through simulation is effective.

Evaluation of Local Material Flow during Complex Deformation Conditions on the Basis of Multi Scale Analysis

2016 ◽  
Vol 682 ◽  
pp. 350-355
Author(s):  
Joanna Szyndler ◽  
Lukasz Madej
Keyword(s):  
Material Flow ◽  
Incremental Forming ◽  
Material Behavior ◽  
Scale Analysis ◽  
Forming Process ◽  
Complex Deformation ◽  
Multi Scale ◽  
Local Material ◽  
Scale Levels ◽  
Digital Material

Development of the multiscale numerical model of innovative incremental forming process, dedicated for manufacturing complex components for the aerospace industry is the main aim of the work. Description of the incremental forming concept based on division of large die into a series of small anvils subsequently pressed into the material is presented within the paper. Particular attention is put on material behavior at both, macro and micro scale levels, respectively. A Finite Element Method (FEM) supported by Digital Material Representation (DMR) concept was used during the investigation. Results in the form of strain distributions and shapes of grains obtained from different sample areas after incremental forming process are presented within the paper.

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