Half axle gears is produced by precision forging popularly because of the advantages in minimum machining allowances, lower material consumption and good service properties. But the forming quality of precision forgin...Half axle gears is produced by precision forging popularly because of the advantages in minimum machining allowances, lower material consumption and good service properties. But the forming quality of precision forging is difficult to control. Many simulations and analysis of precision forging process were taken by previous researchers. But no concrete method is proposed to evaluate and optimize the forming quality of half axel gears. The primary purpose of this work is improving the forming quality of half axel gears by analyzing and optimizing the affected factors of forming quality. The enclosed-die warm forging process of half axle gears was developed, and a new type of die-set used on double action hydraulic press was brought forward. The main influential factors of precision forming quality were analyzed after the forming process had been simulated by using finite element method（FEM）. These factors include die structure, web thickness and web position. A method used to evaluate the forming quality was established, which investigated the maximal forming load, the metal filling rate and the material damage factor. The FEM simulations of half axle gears precision forging were evaluated by this method. The results show that the best forming quality can be achieved when the punches were added with bosses, the web located at the middle plant of the gear, and the web thickness was 30 percent of the inner hole diameter. Verification experiments taking the above optimized parameters were performed on a 7.8 MN double action hydraulic press. The trial products were formed well. And their geometric precision meets the demand. The verification result shows that the optimization of the influential factors, according to the simulations and the evaluation method, can improve the forming quality. The new structure of precision forging die-set and the new evaluation method guarantee a high forming quality ofhalfaxel gears.展开更多
In the existing shearing processes for fabricating parts such as duplex gears, die roll is difficult to avoid. Accordingly, a method based on sheet-bulk metal forming for fabricating a duplex gear with extremely small...In the existing shearing processes for fabricating parts such as duplex gears, die roll is difficult to avoid. Accordingly, a method based on sheet-bulk metal forming for fabricating a duplex gear with extremely small die roll in one stroke is proposed in the current work. The process could be divided into three stages according to the forming features: upsetting and shearing stage, lateral extrusion stage, and local filling stage. The die roll appeared in the shearing stage, which could be reduced in the subsequent extrusion and local filling stages. To reveal the underground mechanism, material flows under two situations, as a key factor to influence the forming quality, were compared and investigated. The results revealed that by controlling material flow, one could avoid the defects and reduce the die roll.展开更多
基金supported by Chongqing Municipal Science and Technology Committee of China (Grant No. 2005AA3012-4)
文摘Half axle gears is produced by precision forging popularly because of the advantages in minimum machining allowances, lower material consumption and good service properties. But the forming quality of precision forging is difficult to control. Many simulations and analysis of precision forging process were taken by previous researchers. But no concrete method is proposed to evaluate and optimize the forming quality of half axel gears. The primary purpose of this work is improving the forming quality of half axel gears by analyzing and optimizing the affected factors of forming quality. The enclosed-die warm forging process of half axle gears was developed, and a new type of die-set used on double action hydraulic press was brought forward. The main influential factors of precision forming quality were analyzed after the forming process had been simulated by using finite element method（FEM）. These factors include die structure, web thickness and web position. A method used to evaluate the forming quality was established, which investigated the maximal forming load, the metal filling rate and the material damage factor. The FEM simulations of half axle gears precision forging were evaluated by this method. The results show that the best forming quality can be achieved when the punches were added with bosses, the web located at the middle plant of the gear, and the web thickness was 30 percent of the inner hole diameter. Verification experiments taking the above optimized parameters were performed on a 7.8 MN double action hydraulic press. The trial products were formed well. And their geometric precision meets the demand. The verification result shows that the optimization of the influential factors, according to the simulations and the evaluation method, can improve the forming quality. The new structure of precision forging die-set and the new evaluation method guarantee a high forming quality ofhalfaxel gears.
基金the National Natural Science Foundation of China (Grant No. 51475296).
文摘In the existing shearing processes for fabricating parts such as duplex gears, die roll is difficult to avoid. Accordingly, a method based on sheet-bulk metal forming for fabricating a duplex gear with extremely small die roll in one stroke is proposed in the current work. The process could be divided into three stages according to the forming features: upsetting and shearing stage, lateral extrusion stage, and local filling stage. The die roll appeared in the shearing stage, which could be reduced in the subsequent extrusion and local filling stages. To reveal the underground mechanism, material flows under two situations, as a key factor to influence the forming quality, were compared and investigated. The results revealed that by controlling material flow, one could avoid the defects and reduce the die roll.
