scholarly journals Distribution of Microstructure and Vickers Hardness in Spur Bevel Gear Formed by Cold Rotary Forging

2014 ◽  
Vol 6 ◽  
pp. 809276 ◽  
Author(s):  
Wuhao Zhuang ◽  
Lin Hua ◽  
Xinghui Han ◽  
Liying Dong
Keyword(s):  
Vickers Hardness ◽  
Gear Tooth ◽  
Effective Strain ◽  
Bevel Gear ◽  
Fe Model ◽  
Software Environment ◽  
Rigid Plastic ◽  
Rotary Forging ◽  
Bevel Gears ◽  
Cold Rotary Forging

Cold rotary forging is a novel metal forming technology which is widely used to produce the high performance gears. Investigating the microstructure and mechanical property of cold rotary forged gears has a great significance in improving their service performance. In this study, the grain morphology in different regions of the spur bevel gear which is processed by cold rotary forging is presented. And the distribution regulars of the grain deformation and Vickers hardness in the transverse and axial sections of the gear tooth are studied experimentally. A three-dimensional rigid-plastic FE model is developed to simulate the cold rotary forging process of a spur bevel gear under the DEFORM-3D software environment. The variation of effective strain in the spur bevel gear has been investigated so as to explain the distribution regulars of the microstructure and Vickers hardness. The results of this research thoroughly reveal the inhomogeneous deformation mechanisms in cold rotary forging of spur bevel gears and provide valuable guidelines for improving the performance of cold rotary forged spur bevel gears.

3D FE Modeling Simulation of Cold Rotary Forging with Double Symmetry Rolls

2009 ◽  
Vol 628-629 ◽  
pp. 623-628
Author(s):  
Xing Hui Han ◽  
Lin Hua ◽  
Yumin Zhao
Keyword(s):  
Innovative Technology ◽  
Fe Model ◽  
Software Environment ◽  
Rotary Forging ◽  
Modeling Simulation ◽  
Forming Technology ◽  
Plastic Forming ◽  
As Stress ◽  
Cold Rotary Forging ◽  
Double Symmetry

A novel metal plastic forming technology, cold rotary forging with double symmetry rolls, is presented on the basis of cold rotary forging with single roll. A reasonable 3D elastic-plastic dynamic explicit FE model of cold rotary forging with double symmetry rolls is developed under the ABAQUS software environment. Through simulation, the distributions and histories of different field-variables such as stress, strain and force and power parameters are investigated in detail. The research results not only provide an advanced and innovative technology for metal plastic forming, but also help to better understand cold rotary forging with double symmetry rolls.

Effect of Position between Upper Die and Workpiece on Cold Rotary Forging

2011 ◽  
Vol 189-193 ◽  
pp. 2547-2552 ◽  
Author(s):  
Xing Hui Han ◽  
Lin Hua
Keyword(s):  
Metal Forming ◽  
Interactive Effects ◽  
Fe Model ◽  
Software Environment ◽  
Forging Process ◽  
Rotary Forging ◽  
Forming Technology ◽  
Cylindrical Workpiece ◽  
Forging Force ◽  
Cold Rotary Forging

Cold rotary forging is an advanced but very complex incremental metal forming technology with multi-factors coupling interactive effects. The position between the upper die and the workpiece has a significant effect on the cold rotary forging process. In the current work, a 3D elastic-plastic dynamic explicit FE model of cold rotary forging of a cylindrical workpiece is developed under the ABAQUS software environment and its validity has been verified experimentally. On the basis of this reliable 3D FE model, the effects of the position between the upper die and the workpiece on the cold rotary forging process have been thoroughly revealed. The results show that with increasing the distance between the pivot point of the upper die and the centre of the workpiece, the deformation of the workpiece becomes more inhomogeneous and the maximum axial forging force and forging moment gradually increase. The results of this research not only provide valuable guidelines for the installation and adjustment of dies in the cold rotary forging process, but also help to better understand the deformation mechanisms of cold rotary forging.

The Finite Element Simulation Used in Straight Tooth Bevel Gear’s Vibration Rotary Forging

2012 ◽  
Vol 430-432 ◽  
pp. 1716-1720
Author(s):  
Gai Pin Cai ◽  
Xiao Hui Zhao ◽  
Hong Tao Su
Keyword(s):  
Finite Element ◽  
Metal Flow ◽  
Bevel Gear ◽  
Forming Process ◽  
Rigid Plastic ◽  
Element Analysis ◽  
Rotary Forging ◽  
Bevel Gears ◽  
Element Simulation ◽  
Vibration Parameters

Vibration rotary forging is a complex precision forming process. In the forming process, the addition of the vibration make the boundary condition and the friction condition of the gear blank and the mould changed with the rotation of the head, which lead the forming process of the spur bevel gears become more complicated. Using the rigid-plastic finite element method to study the metal flow law and the stress distribution of the gear blank during the forming process of the spur bevel gears. Using the DEFORM-3D finite element analysis software to simulate and analysis the forming process of the spur bevel gear, in order to get the forming law of the bevel gear during the different type of the vibration parameters.

Reverse on the Spiral Bevel Gear’s Teeth Profile Line

2011 ◽  
Vol 308-310 ◽  
pp. 1596-1599
Author(s):  
Chun Xiang Wang ◽  
Jing Qiang Zhang ◽  
Zhi Jun Liu
Keyword(s):  
Gear Tooth ◽  
Bevel Gear ◽  
Measuring System ◽  
Gear Teeth ◽  
Bevel Gears ◽  
Profile Line ◽  
Simple Processing ◽  
Base Circle ◽  
Spiral Bevel ◽  
Reverse Method

For the purposes of spiral bevel gears of cycloid gear is more and more extensive, the research on the reverse are rare phenomenon, this paper puts forward a reverse method: It’s based on three coordinates measuring system for prolate epicycloids’ bevel gear teeth profile. This method according to the forming principle of the spiral bevel gear tooth profile, with the back cone expanding the measured data of a group of good quality after simple processing, according to the involutes’ parameter equation for theoretical analysis, reverse out the base circle radius and modulus, make the bevel gear tooth profiles to reverse.

The Undercutting of Circular-Cut Spiral Bevel Gears

1992 ◽  
Vol 114 (2) ◽  
pp. 317-325 ◽  
Author(s):  
Zhang-Hua Fong ◽  
Chung-Biau Tsay
Keyword(s):  
Gear Tooth ◽  
Sufficient Conditions ◽  
Bevel Gear ◽  
Tooth Surface ◽  
Spiral Bevel Gear ◽  
Spiral Bevel Gears ◽  
Bevel Gears ◽  
Tooth Surfaces ◽  
Sufficient And Necessary Conditions ◽  
Spiral Bevel

Undercutting is a serious problem in designing spiral bevel gears with small numbers of teeth. Conditions of undercutting for spiral bevel gears vary with the manufacturing methods. Based on the theory of gearing [1], the tooth geometry of the Gleason type circular-cut spiral bevel gear is mathematically modeled. The sufficient and necessary conditions for the existence and regularity of the generated gear tooth surfaces are investigated. The conditions of undercutting for a circular-cut spiral bevel gear are defined by the sufficient conditions of the regular gear tooth surface. The derived undercutting equations can be applicable for checking the undercutting conditions of spiral bevel gears manufactured by the Gleason Duplex Method, Helical Duplex Method, Fixed Setting Method, and Modified Roll Method. An example is included to illustrate the application of the proposed undercut checking equations.

3D FE Modeling Simulation for Wear in Cold Rotary Forging of 20CrMnTi Alloy

2012 ◽  
Vol 135 (1) ◽  
Author(s):  
Xinghui Han ◽  
Lin Hua
Keyword(s):  
Metal Forming ◽  
Fe Model ◽  
Fe Method ◽  
Workpiece Surface ◽  
Rotary Forging ◽  
Forming Technology ◽  
Inner Diameter ◽  
Wear Response ◽  
Distance Response ◽  
Cold Rotary Forging

Cold rotary forging is an advanced but complicated metal forming technology with continuous local plastic deformation. Investigating the wear is significant for effectively predicting the life of the dies and improving the workpiece surface quality. This paper is aimed to use the FE method to predict the wear response over the surfaces of the dies and the workpiece in cold rotary forging. For this purpose, a 3D elastic-plastic dynamic explicit FE model of cold rotary forging of 20CrMnTi alloy is developed using the FE software ABAQUS/Explicit and its validity is verified theoretically and analytically. Based on this valid 3D FE model, a systematic study has first been conducted, modeling and explaining the contact pressure and slip distance response. Then, the wear response that occurs at the surfaces of the dies and the workpiece is achieved. Finally, the effect of the process parameters, rotational speed n of the upper die, feed rate v of the lower die, outer/inner diameter of the ring workpiece, on the wear response is revealed. The results of this research help us better understand the complicated wear mechanisms in cold rotary forging. Moreover, the modeling methods proposed in this paper have the general significance to study the wear problems in other complicated metal forming processes.

General Plate Formula for Bevel Gears with Back Shoulder

1985 ◽  
Vol 9 (3) ◽  
pp. 131-136
Author(s):  
E.M. Al-Shareedah ◽  
T.F. Lehnhoff
Keyword(s):  
Finite Element ◽  
Finite Element Modelling ◽  
Gear Tooth ◽  
Bevel Gear ◽  
Energy Approach ◽  
Modelling Technique ◽  
Design Equation ◽  
Element Modelling ◽  
Bevel Gears ◽  
Gear Manufacturing

Strength of bevel gears can be increased substantially if a web support is provided the back of their teeth. This web can be obtained by either cutting gears through a special gear manufacturing operation, or through the technique of gear forging. In this analysis, the strength due to this back web support is investigated. The new gear tooth configuration, which resembles a plate supported at two adjacent edges is analyzed. The variational energy approach and a finite element modelling technique was also used to analyze six bevel gears. The resulting design equation describes the characteristics of deflection of this new bevel gear tooth more closely than the well-known Lewis design equation.

Designing and Manufacturing Spiral Bevel Gears Using 5-Axis CNC Milling Machines

2011 ◽  
Author(s):  
Joe¨l Teixeira Alves ◽  
Miche`le Guingand ◽  
Jean-Pierre de Vaujany
Keyword(s):  
Manufacturing Process ◽  
Gear Tooth ◽  
Bevel Gear ◽  
Spiral Bevel Gear ◽  
Milling Machine ◽  
Cnc Milling ◽  
Spiral Bevel Gears ◽  
Bevel Gears ◽  
Tooth Surfaces ◽  
Spiral Bevel

The design of spiral bevel gears still remains complex since tooth geometry and the resulting kinematics performance stem directly from the manufacturing process. Spiral bevel gear manufacture owes most to the works of Gleason and Klingelnberg. However, recent advances in milling machine technology and CAM (Computer Aided Manufacturing) make it possible to manufacture good quality spiral bevel gears on a standard 5-axis milling machine. This paper describes the CAD definition and manufacturing of spiral bevel gear tooth surfaces. Process performance is assessed by comparing the resulting surfaces after machining with the pre-defined CAD surfaces. Using this manufacturing process allows to propose new type of geometry. This one is more theoretical and, in some respects, easier to design than the standard spiral bevel gear as it enables simpler mesh optimization. The latter can be achieved by using the model of meshing under load recalled in this paper.

Numerical Simulation of Cold Heading and Extruding for Spiral Bevel Gear

2010 ◽  
Vol 139-141 ◽  
pp. 1202-1205
Author(s):  
Ying Ying Chen ◽  
Wen Jie Feng ◽  
Ying Yang ◽  
Yong Du
Keyword(s):  
Bevel Gear ◽  
Forming Process ◽  
Rigid Plastic ◽  
Flow Process ◽  
Bevel Gears ◽  
Finite Element Software ◽  
Optimum Diameter ◽  
Spiral Bevel ◽  
Deform 3D

This paper develops an opened forging and divided flow process for spiral bevel gears. By the help of rigid-plastic finite-element software DEFORM-3D, this paper designed cold-extruding part and concave die for bevel gear in the rear running gear of tri-motorcycle and simulated the forming process of cold-heading and extruding. On condition of guaranteeing shaping quality of teeth, the optimum diameter of die porthole was made sure by analyzing the effect of porthole size on volume of billet and plastic force. The experiment results show that the design parameter is reasonable and simulation results are helpful to the design of die.

Intermediate Slabs and Optimization in Forging Process of Balance Elbow by FEM

2014 ◽  
Vol 721 ◽  
pp. 127-130
Author(s):  
Bo Jun Xiong ◽  
Ke Lu Wang ◽  
Jun Fang ◽  
Yun Huang
Keyword(s):  
Temperature Distribution ◽  
Strain Distribution ◽  
Simulation Analysis ◽  
Effective Strain ◽  
Maximum Load ◽  
Load Force ◽  
Fe Model ◽  
Forming Process ◽  
Rigid Plastic ◽  
Forging Process

Based on Deform-3D software, a 3D rigid-plastic FE model of forging forming process was established, then simulation analysis effective strain distribution, temperature distribution and load-stroke curve of three kinds of intermediate slabs (S1,S2,S3) in forging process. The results show that the optimized intermediate slab (S3) of effective strain distribution and temperature distribution is most homogeneous. And the maximum load force is minimum, the Shapes and dimensions of forging reach the preset value.

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