Effect of key factors on cold orbital forging of a spur bevel gear

Abstract

Cold orbital forging is an advanced spur bevel gear forming technology. Generally, the spur bevel gear in the cold orbital forging process is formed by two steps: the preforming step and the final step. Due to the great importance of the final step to gear forming and its complication with interactive factors, this work aims at examining the influence of key factors on the final step in cold orbital forging of a spur bevel gear. Using the finite element (FE) method and control variate method, the influence rules of four key factors, rotation velocity of the upper tool, n, feeding velocity of the lower tool, v, tilted angle of the upper tool, γ, friction factor between the tools and the billet, m, on the geometry and the deformation inhomogeneity of the cold orbital forged gear are thoroughly clarified. The research results show that the flash becomes more homogeneous with increasing v, increasing m, decreasing n or decreasing γ. And the deformation of the gear becomes more homogeneous with increasing v, decreasing n or decreasing γ. Finally, a corresponding experiment is conducted, which verifies the accuracy of FE simulation conclusions.

Keywords

cold orbital forging / FE modeling / key factors / spur bevel gears

References

[1] HawkyardJ B, GurnaniC, KS, JohnsonW. Pressure-distribution measurements in rotary forging [J]. Journal of Mechanical Engineering Science, 1977, 19: 135-142

[2] PeiX H, ZhouD C, WangZ RSome basic problems of the rotary forging and its application [C]//Proceedings of the Second International Conference on Rotary Metalworking Processes, 198281-90

[3] HanX-h, HuaLin. Prediction of contact pressure, slip distance and wear in cold rotary forging using finite element methods [J]. Tribology International, 2011, 44(12): 1742-1753

[4] HanX-h, HuaLin. Investigation on contact parameters in cold rotary forging using a 3D FE method [J]. International Journal of Advanced Manufacturing Technology, 2012, 62(9/10/11/12): 1087-1106

[5] HanX-h, HuaLin. 3D FE modelling of contact pressure response in cold rotary forging [J]. Tribology International, 2013, 57: 115-123

[6] AppletonE, SlaterR A C. Effects of upper platen configuration in the rotary forging process and rotary forging into a contoured lower platen [J]. International Journal of Machine Tool Design and Research, 1973, 13(1): 43-62

[7] ZhangMengCalculating force and energy during rotary forging [C]//Proceedings of the Third International Conference on Rotary Metalworking Processes, 1984115-124

[8] OudinJ, RavalardY, VerwaerdeG, GelinJ C. Force, torque and plastic flow analysis in rotary upsetting of ring shaped billets [J]. International Journal of Mechanical Sciences, 1985, 27(11/12): 761-780

[9] HawkyardJ B, SmithC P. The influence of elastic die distortion on forming force in rotary forging [J]. International Journal of Mechanical Sciences, 1988, 30(8): 533-542

[10] CantaT, FrunzaD, SabadusD, TintelecanC. Some aspects of energy distribution in rotary forming processes [J]. Journal of Materials Processing Technology, 1998, 80/81: 195-198

[11] ZhouD-c, HanY-d, WangZ R. Research on rotary forging and its distribution of deformation [J]. Journal of Materials Processing Technology, 1992, 31(1/2): 161-168

[12] ChoiS, NaK H, KimJ H. Upper-bound analysis of the rotary forging of a cylindrical billet [J]. Journal of Materials Processing Technology, 1997, 67(1): 78-82

[13] Kalinowska-OzgowiczE, KrukiewiczW, KowalskiL, KozikR, RabusJ, SzotaJ G. Orbital forming of an oxygen cylinder web [J]. Journal of Materials Processing Technology, 1997, 64(1): 215-222

[14] WangG-c, GuanJ, ZhaoG-qun. A photo-plastic experimental study on deformation of rotary forging a ring workpiece [J]. Journal of Materials Processing Technology, 2005, 169(1): 108-114

[15] HuaL, HanX-hui. 3D FE modeling simulation of cold rotary forging of a cylinder workpiece [J]. Materials and Design, 2009, 30(6): 2133-2142

[16] HanX-h, HuaLin. Effect of size of the cylindrical workpiece on the cold rotary-forging process [J]. Materials and Design, 2009, 30(8): 2802-2812

[17] HanX-h, HuaLin. 3D FE modeling of cold rotary forging of a ring workpiece [J]. Journal of Materials Processing Technology, 2009, 209(12/13): 5353-5362

[18] HanX-h, HuaLin. Comparison between cold rotary forging and conventional forging [J]. Journal of Mechanical Science and Technology, 2009, 23(10): 2668-2678

[19] LiuG, YuanS J, WangZ R, ZhouD C. Explanation of the mushroom effect in the rotary forging of a cylinder [J]. Journal of Materials Processing Technology, 2004, 151(1/2/3): 178-182

[20] ZhouD-c, YuanS-j, WangZ R, XiaoZ-rui. Defects caused in forming process of rotary forged parts and their preventive methods [J]. Journal of Materials Processing Technology, 1992, 32(1/2): 471-479

[21] OhH K, ChoiS. Ductile fracture in the central region of a circular plate in rotary forging [J]. Journal of Materials Processing Technology, 1997, 68(1): 23-26

[22] OhH K, ChoiS. A study on center thinning in the rotary forging of a circular plate [J]. Journal of Materials Processing Technology, 1997, 66(1): 101-106

[23] LeeJ J, JungU J, ParkG J. Shape optimization of the workpiece in the forging process using equivalent static loads [J]. Finite Elements in Analysis and Design, 2013, 69: 1-18

[24] BrinksmeierE, LubbenT, FritschingU, CuiC-s, RentschR, SolterJ. Distortion minimization of disks for gear manufacture [J]. International Journal of Machine Tools and Manufacture, 2011, 51(4): 331-338

[25] SongJ H, ImY T. Process design for closed-die forging of bevel gear by finite element analyses [J]. Journal of Materials Processing Technology, 2007, 192/193: 1-7

[26] HuC-l, WangK-s, LiuQ-kun. Study on a new technological scheme for cold forging of spur gears [J]. Journal of Materials Processing Technology, 2007, 187/188: 600-603

[27] 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

[28] YangS, SongY-l, ZhangMei. Effects of parameters on rotational fine blanking of helical gears [J]. Journal of Central South University, 2014, 21(1): 50-57

[29] DengX-b, HuaL, HanX-h, SongY-li. Numerical and experimental investigation of cold rotary forging of a 20CrMnTi alloy spur bevel gear [J]. Materials and Design, 2011, 32(3): 1376-1389

[30] HanX-h, HuaL, ZhuangW-h, ZhangX-chang. Process design and control in cold rotary forging of non-rotary gear parts [J]. Journal of Materials Processing Technology, 2014, 214(11): 2402-2416

[31] SamolykG. Investigation of the cold orbital forging process of an AlMgSi alloy bevel gear [J]. Journal of Materials Processing Technology, 2013, 213(10): 1692-1702