Finite element analysis and simulation for cold precision forging of a helical gear

Abstract

To investigate the effects of billet geometry on the cold precision forging process of a helical gear, six different billet geometries were designed utilizing the relief-hole principle. And the influences of the billet geometry on the forming load and the deformation uniformity were analyzed by three-dimensional (3D) finite element method (FEM) under the commercial software DEFORM 3D. The billet geometry was optimized to meet lower forming load and better deformation uniformity requirement. Deformation mechanism was studied through the distribution of flow velocity field and effective strain field. The forging experiments of the helical gear were successfully performed using lead material as a model material under the same process conditions used in the FE simulations. The results show that the forming load decreases as the diameter of relief-hole d₀ increases, but the effect of d₀ on the deformation uniformity is very complicated. The forming load is lower and the deformation is more uniform when d₀ is 10 mm.

Keywords

helical gear / cold precision forging / finite element simulation / relief-hole principle

References

[1] YangT. S.. Prediction of maximum forming load and billet dimensions using an abductive network and finite element method simulation of a near net-shaped helical gear forging [J]. Proc Inst Mech Eng B — J Eng Manuf, 2009, 223: 289-304

[2] JinJ.-s., XiaJ.-c., WangX.-y., HuG.-a., LiuHua.. Die design for cold precision forging of bevel gear based on finite element method [J]. Journal of Central South University of Technology, 2009, 16(4): 546-551

[3] LiY.-h., LiuH., LiuD., WangW.-q., SunH.-x., LiuB.-xuan.. Numerical simulation of cold precision forming process for helical gear [J]. Journal of Mechanical Transmission, 2010, 34(3): 1-3

[4] ChoiJ. C., ChoiY., TakS. J.. The forging of helical gears (I): Experiments and upper-bound analysis [J]. International Journal Mechanical Science, 1998, 40: 325-337

[5] ChoiJ. C., ChoiY., TakS. J.. The forging of helical gears (II): Comparisons of the forging processes [J]. International Journal Mechanical Science, 1999, 41: 725-739

[6] SadeghiM. H., DeanT. A.. Precision forging straight and helical spur gears [J]. Journal of Materials Processing Technology, 1994, 45: 25-30

[7] SadeghiM. H., DeanT. A.. The ejection of precision-forged straight and helical spur-gear forms [J]. Journal of Materials Processing Technology, 1992, 31: 147-160

[8] SzentmihalyiV., LangeK., TronelY., ChenotJ. L., DuclouxR.. 3-D finite-element simulation of the cold forging of helical gears [J]. Journal of Materials Processing Technology, 1994, 43: 279-291

[9] LangeK., SzentmihalyiV.. Optimized cold forging of helical gears by FEM-simulation [C]. Proceedings of the Ninth International Congress on Cold Forging, 1995Solihull, UKFMJ International283-289

[10] ParkY. B., YangD. Y.. Finite element analysis for precision cold forging of helical gear using recurrent boundary conditions [J]. Proc Inst Mech Eng B — J Eng Manuf, 1998, 212: 96-301

[11] JungS. Y., KangM. C., KimC., KimC. H., ChangY. J., HanS. M.. A study on the extrusion by a two-step process for manufacturing helical gear [J]. International Journal of Advanced Manufacturing Technology, 2009, 41: 684-693

[12] KamounehA. A., NiJ., StephensonD., VriesenR., DegracG.. Diagnosis of involutometric issues in flat rolling of external helical gears through the use of finite-element models [J]. International Journal of Machine Tools & Manufacture, 2007, 47: 1257-1262

[13] KimS. Y., KubotaS., YamanakaM.. Application of CAE in cold forging and heat treatment processes for manufacturing of precision helical gear part [J]. Journal of Material Processing Technology, 2008, 201: 25-31

[14] DengX.-b., HuaL., HanX.-h., SongY.-li.. Numerical and experimental investigation of cold rotary forging of a 20CrMnTi alloy spur bevel gear [J]. Material and Design, 2011, 32: 1376-1389

[15] JinJ.-s., XiaJ.-c., WangX.-y., JiD.-s., LiuHua.. Three-dimensional finite element analysis and optimization of helical gear cold extrusion process [C]. Proceedings of the Third China Academic Congress on Precision Forging, 2008Yancheng, ChinaCPES85-91

[16] FengW., HuaLin.. Multi-objective optimisation of process parameters for the helical gear precision forging by using Taguchi method [J]. Journal of Mechanical Science and Techonology, 2011, 25(6): 1519-1527

[17] FengW., HuaLin.. Process parameters optimisation for helical gears precision forging with damage minimization [C]. International Conference on Digital Manufacturing & Automation, 2010Changsha, ChinaIEEE117-120

[18] OguraM., KondoK.. Precision forging of helical gears utilizing divided-flow method [C]. The Seventh Asia Symposium on Precision Forging, 2000Guilin, ChinaJSTP67-70

[19] KondoK., JitsunariT., OhgaK.. Investigations on cold die forging of a gear utilizing divided flow^(1st report, examination of applicable condition for a spur gear) [J]. JSME, 1985, 28: 2442-2450

[20] FengW., MeiY.-f., YanK., ZouT., ZhangX.-lei.. Billet design optimization of helical gears precision forging based on response surface method and FEM simulation [J]. Advanced Materials Research, 2011, 189-193: 4168-4172

[21] TanX.-f., LiuX., XiongH.-m., LiJ.-h., YangJ.-hua.. Simulation and experimental research on the precision forging of spur gear [J]. Journal of Plasticity Engineering, 2010, 17(1): 22-26