Advertisement

A new forming method of straight bevel gear using a specific die with a flash

  • Zhenchao QiEmail author
  • Xingxing Wang
  • Wenliang Chen
ORIGINAL ARTICLE
  • 12 Downloads

Abstract

Due to high forming load and serious die wear, the large diameter straight bevel gear is seldom to manufacture by forging. A new forming method is proposed to manufacture the straight bevel gear by a specific die with a flash and a boss, and the forming load and die wear are regarded as the optimization targets. Die with a flash is significant to reduce the load and die wear. However, the small-end section and large-end section of tooth surface is incomplete filling. Therefore, a flash and a boss are combined to design in die to make sure low forming load and good precision accuracy. Firstly, according to the load and die wear results of traditional forging process by Deform-3D, a flash and a boss are designed in the final forming die of three and two steps, and the two-step process is determined by the comparison of load and die wear. Secondly, test plans of the pre-forging and final forging dies are carried out using Taguchi, and the structure of the pre-forging and final forging dies are analyzed and optimized. Thirdly, test plans of the pre-forging and final forging process parameters are established by response surface analysis (RSA), and the optimal scheme of parameter is determined. Finally, physical experiments and practice forging are proceeded to certify the optimal results of finite element (FE), and the results of experiments and FE have a good consistency.

Keywords

Straight bevel gear Flash Deform-3D Taguchi Response surface analysis 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

Notes

Acknowledgements

The work reported herein is sponsored by the National Natural Science Foundation of China (51605221). The authors would like to acknowledge the editors and the anonymous referees for their insightful comments.

References

  1. 1.
    Wang ZG, Hirasawa K, Yoshikawa Y, Osakada K (2016) Forming of light-weight gear wheel by plate forging. CIRP Ann 65(1):293–296CrossRefGoogle Scholar
  2. 2.
    Dobrzański LA, Tański T, Čížek L, Brytan Z (2007) Structure and properties of magnesium cast alloys. J Mater Process Technol 192-193:567–574CrossRefGoogle Scholar
  3. 3.
    Politis DJ, Lin J, Dean TA, Balint DS (2014) An investigation into the forging of Bi-metal gears. J Mater Process Technol 214(11):2248–2260CrossRefGoogle Scholar
  4. 4.
    Wang Y, Lan Z, Hou L, Zhao H, Zhong Y (2015) A precision generating grinding method for face gear using CBN wheel. Int J Adv Manuf Technol 79:1839–1848CrossRefGoogle Scholar
  5. 5.
    Wang Y, Lan Z, Hou L, Chu X, Yin Y (2016) An efficient honing method for face gear with tooth profile modification. Int J Adv Manuf Technol 90:1155–1163CrossRefGoogle Scholar
  6. 6.
    Jung S-Y, Kang M-C, Kim C, Kim C-H, Chang Y-J, Han S-M (2009) A study on the extrusion by a two-step process for manufacturing helical gear. Int J Adv Manuf Technol 41:684–693CrossRefGoogle Scholar
  7. 7.
    Debin S, Jie X, Chunju W, Bin G (2009) Hybrid forging processes of micro-double gear using micro-forming technology. Int J Adv Manuf Technol 44:238–243CrossRefGoogle Scholar
  8. 8.
    Zhuang W, Hua L, Han X, Zheng F (2017) Design and hot forging manufacturing of non-circular spur bevel gear. Int J Mech Sci 133:129–146CrossRefGoogle Scholar
  9. 9.
    Bochniak W, Korbel A, Szyndler R, Hanarz R, Stalony-Dobrza’nski F, Błaż L, Snarski P (2005) New forging method of bevel gears from structural steel. J Mater Process Technol 173:75–83CrossRefGoogle Scholar
  10. 10.
    Gao Z-S, Li J-B, Deng X-Z, Yang J-J, Chen F-X, Xu A-J, Li L (2017) Research on gear tooth forming control in the closed die hot forging of spiral bevel gear. Int J Adv Manuf Technol 94:2993–3004CrossRefGoogle Scholar
  11. 11.
    Wang W, Zhao J, Zhai R (2016) A forming technology of spur gear warm extrusion and the defects control. J Manuf Process 2016:30–38CrossRefGoogle Scholar
  12. 12.
    Zhang Q, Ben N-y, Yang K (2017) Effect of variational friction and elastic deformation of die on oscillating cold forging for spline shaft. J Mater Process Technol 244:166–177CrossRefGoogle Scholar
  13. 13.
    Ohrn KE (2007) Encyclopaedia of energy engineering and technology. Press Taylor & Francis:24–30Google Scholar
  14. 14.
    Song JH, Im Y-T (2007) Process design for closed-die forging of bevel gear by finite element analyses. J Mater Process Technol 193:1–7CrossRefGoogle Scholar
  15. 15.
    Hawryluk M, Jakubikt J (2016) Analysis of forging defects for selected industrial die forging process. Eng Fail Anal 59:396–409CrossRefGoogle Scholar
  16. 16.
    Liu Y, Wu Y, Wang J, Liu S (2017) Defect analysis and design optimization on the hot forging of automotive balance shaft based on 3D and 2D simulations. Int J Adv Manuf Technol 18:8–15Google Scholar
  17. 17.
    Zhang D-W, Li S-P, Jing F, Fan S-Q, Zhao S-D (2018) Initial position optimization of preform for large-scale strut forging. Int J Adv Manuf Technol 94:2803–2810CrossRefGoogle Scholar
  18. 18.
    Liu Y, Wang J, Wang D (2017) Numerical optimization on hot forging process of connecting rods based on RSA with experimental verification. Int J Adv Manuf Technol 90:3129–3135CrossRefGoogle Scholar
  19. 19.
    Langner J, Stonis M, Behrens B-A (2016) Investigation of a moveable flash gap in hot forging. J Mater Process Technol 2031:199–208CrossRefGoogle Scholar
  20. 20.
    Tomov B, Radev R, Gagov V (2004) Influence of flash design upon process parameters of hot die forging. J Mater Process Technol 157-158:620–623CrossRefGoogle Scholar
  21. 21.
    Equbala MI, Kumar R, Shamim M, Ohdar RK (2014) A grey-based Taguchi method to optimize hot forging process. Procedia Materials Sci 6:1495–1504Google Scholar
  22. 22.
    Khalilpourazary S, Dadvand A, Azdas T, Sadeghi MH (2011) Design and manufacturing of a straight bevel gear in hot precision forging process using finite volume method and CAD/CAE technology. Int J Adv Manuf Technol 56:87–95CrossRefGoogle Scholar
  23. 23.
    Battelle (1993) Scientific forming technologies corporation, Deform-2D Columbia, OhioGoogle Scholar
  24. 24.
    Bortoleto EM, Rovani AC, Sericopi V (2013) Experimental and numerical analysis of dry contact in the pin on disc test. Wear 301:19–26CrossRefGoogle Scholar
  25. 25.
    Ross TJ (1988) Taguchi techniques for quality engineering. McGraw-Hill Book Company, New YorkGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2018

Authors and Affiliations

  1. 1.College of Mechanical and Electrical EngineeringNanjing University of Aeronautics and AstronauticsNanjingChina

Personalised recommendations