Sheet Bulk Forming of Thin-Walled Components with External Gearing through Upsetting Using Controllable Deformation Zone Method

Sheet-bulk metal forming(SBMF)is a promising process for manufacturing complex sheet components with functional elements.In this study,the entire forming process for a typical thin-walled component with external gearing is investigated,including sheet forming and bulk forming processes.Deep drawn cups are prepared during sheet forming;subsequently,upsetting is performed on the sidewall to form external gearing.The upsetting method performed is known as upsetting with a controllable deformation zone(U-CDZ).Compared with the conventional upsetting method,a floating counter punch with a counter force is used in the U-CDZ method such that the forming mechanism is changed into the accumulation of the deformation zone instead of deformation throughout the entire sidewall.The effects of the counter force and material flow are investigated to understand the mechanism.The forming quality,i.e.,the formfilling and effective strain distribution,improved,whereas a high forming load is avoided.In addition,a punch with a lock bead is used to prevent folding at the inner corner during the experiment.

直齿外插齿刀变位系数的新解法

变位系数的计算是插齿刀设计的重要工作。本文讨论了插齿刀变位系数满足产生齿顶变尖、被切齿轮齿根的过渡曲线干涉、根切和顶切等四个约束条件的选取原则。给出了设计新刀的最大变位系数和最小变位系数计算公式,通过编制的插齿刀变位系数计算机辅助运算流程,从中优选之结果插齿刀设计计算简单快捷,且便于判断设计的正确性。