Study on precision forging process of spur gear in parking brake

2010 ◽  
Author(s):  
Cheng-Liang Hu ◽  
Li Wang ◽  
Zhen Zhao ◽  
Hai-Ying Zhang ◽  
Yi-Hua Wang
Keyword(s):  
Spur Gear ◽  
Forging Process ◽  
Precision Forging ◽  
Parking Brake

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.

Development of Process Optimization for an Intelligent Knowledge-Based System for Spur Gear Precision Forging Die Design

2004 ◽  
Author(s):  
El-Sayed Aziz ◽  
C. Chassapis
Keyword(s):  
Parametric Design ◽  
Metal Flow ◽  
Optimization Method ◽  
Spur Gear ◽  
Die Design ◽  
Design System ◽  
Process Conditions ◽  
System Utilization ◽  
Forging Process ◽  
Precision Forging

Forging sequence design is mainly carried out using empirical rules for the design of the intermediate die shapes, in addition to many trail-and-error runs resulting in prolonged development times and higher costs. An integrated optimal design of preform shapes and process conditions approach to minimize the energy required is essential. The research presented in this article aims at developing an optimization algorithm to determine the optimum intermediate die shape-designs that minimize the total energy required during the forging process sequence. It is based on the results obtained in the previous research with focus on knowledge base and database representation to design precision forging solid gears and provide detailed process specification. A three-step algorithm, which addresses gear construction design, manufacturability analysis of gear construction and die-design optimization, is used to generate the parametric gear model and automatically extract design information for manufacturing process planning based on the feature-based parametric design system. Utilization of the shape optimization method for preform stages avoids costly production problems. The optimized approach provides accurate description of all stages involved in the forging process. Forging load and energy required, along with metal flow and detailed geometry specification of die forms for every forging stage are obtained. The forging energy requirements based on this approach are as much as 25% lower than those arrived from die designs based on actual tooth profile geometry.

Investigation of Precision Forging Process of Spur Gears: Numerical Analysis and Experiments

2011 ◽  
Vol 341-342 ◽  
pp. 265-270
Author(s):  
M. Zadshakoyan ◽  
E.Abdi Sobbouhi ◽  
H. Jafarzadeh
Keyword(s):  
Numerical Analysis ◽  
Effective Strain ◽  
Spur Gear ◽  
Model Material ◽  
Optimum Number ◽  
Spur Gears ◽  
Specific Pressure ◽  
Rigid Plastic ◽  
Forging Process ◽  
Precision Forging

In this study, the precision forging process of spur gears has been investigated by means of numerical analysis. The effect of some parameters such as teeth number and module on the forming force and specific pressure were presented. The simulation works were performed rigid-plastic finite element method using DEFORM 3D software. In order to validate the estimated numerical results, they were compared with those obtained experimentally during precision forging of spur gear using lead as a model material. Results showed that the optimum number of gear teeth is between 10 to 20, that is because of being the specific pressure in its minimum value. Also the results obtained from analyzing the effective strain distribution showed that the maximum strain is located on the root area of the teeth. The work presented in this paper might be used for basic data in the design of the precision forging process.

Finite Element Analysis and Optimization of Deformation Behavior for Spur Gear Warm Forging Process

2010 ◽  
Vol 148-149 ◽  
pp. 854-858
Author(s):  
Shu Bo Xu ◽  
Cai Nian Jing ◽  
Ke Ke Sun ◽  
Guo Cheng Ren ◽  
Gui Qing Wang
Keyword(s):  
Finite Element ◽  
Spur Gear ◽  
Spur Gears ◽  
Element Analysis ◽  
Helical Gears ◽  
Forging Process ◽  
Precision Forging ◽  
Die Forging ◽  
Closed Die Forging ◽  
Warm Forging

Recent years have therefore seen growing interest in gear precision forging to net-shape form of forge bevel, spur and helical gears, as an alternative to conventional manufacturing. In this paper, gear precision forging processes are simulated by using metal forming finite element code DEFORM-3D. The investigations of gear precision forging processes are conducted with perform forging and final forging processes. The processes of completely closed-die forging, moving-die forging and central divided flow forging processes are investigated for spur gears. The effect of different processes on the distribution of effective stress in the workpieces and forging loads are given. The purpose of this study is to introduce a new method, a so-called floating-relief method which applied to the forging of spur gears. It indicated that the flowing properties of the gear billet have a higher improve than that of conventional forging process. And the forging load obtained by using this new precision forging technology is decline sharply. The floating-relief method for gear precision forging is a sound process in the practical application.

Numerical Simulation on Precision Forging Process for Spur-Gear with Large Module

2012 ◽  
Vol 538-541 ◽  
pp. 927-931
Author(s):  
Gui Hua Liu ◽  
Zhi Ping Zhong ◽  
Yi Bian ◽  
Qian Li
Keyword(s):  
Numerical Simulation ◽  
Finite Element Method ◽  
Finite Element ◽  
Material Flow ◽  
Spur Gear ◽  
Cold Extrusion ◽  
Forging Process ◽  
Precision Forging ◽  
Warm Forging ◽  
Forging Force

The whole precision forging process of spur-gear with large module (module: 4) including warm forging, cold extrusion and cold sizing is analyzed. By using finite element method, cold sizing step of spur-gear basing on hollow-divided-flow method is simulated, the influenc of hollow diameter on the forging force and material flow is discussed in detail. Futher research shows that appropriate different tooth reduction is benefit to forming tooth profile without mechaning after forging. According to the research, to form such spur gear with module 4 and breadth 59mm studied in this paper, the hollow diameter should be 18mm and the tooth reduction should be 1.2mm. The necessary reference and basis to realize practical precision forging process of spur gear with large module is provided eventually.

Three-Dimensional Numerical Simulation and Forming Investigation for Net-Shape Forging of Spur Gears

2010 ◽  
Vol 139-141 ◽  
pp. 626-629
Author(s):  
Shu Bo Xu ◽  
Cai Nian Jing ◽  
Gui Qing Wang ◽  
Guo Cheng Ren
Keyword(s):  
Numerical Simulation ◽  
Three Dimensional ◽  
Spur Gear ◽  
Systematic Investigation ◽  
Spur Gears ◽  
Stress Distributions ◽  
Forging Process ◽  
Precision Forging ◽  
Finite Element Numerical Simulation ◽  
Forging Die

In this paper, a new precision forging technique composite processing of the moving-die forging and divided flow forging process to form the spur gear is introduced. A systematic investigation of the floating-relief method process is performed by using finite element numerical simulation. The stress distributions on the workpieces were obtained. The closer the die teeth corner is, the higher stress value results can be acquired. And the effective stress is concentrated in spur gears forging die cavity corner. It was found that the floating-relief method forging process with upper and lower convex punches control the material flow effectively and the tooth cavity is filled successfully during the performing forging and final forging. The proposed method can serve as preconditions to analyze the abrasion and fatigue of spur gears forging die. The obtained results can offer valuable guidelines for gear precision forging experiments and practical process planning.

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