Reduction of die roll height in duplex gears through a sheet-bulk metal forming method

doi:10.1007/s40436-018-00245-y

Advances in Manufacturing ›› 2019, Vol. 7 ›› Issue (1): 42-51.doi: 10.1007/s40436-018-00245-y

• ARTICLES • Previous Articles Next Articles

Reduction of die roll height in duplex gears through a sheet-bulk metal forming method

Xiao-Long Sun¹, Xin-Cun Zhuang¹, Feng-Chun Yang¹, Zhen Zhao^1,2

1 Institute of Forming Technology and Equipment, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200030, People's Republic of China;
2 National Engineering Research Center of Die & Mold CAD, Shanghai Jiao Tong University, Shanghai 200030, People's Republic of China

Received:2018-07-31 Online:2019-03-25 Published:2019-03-22
Contact: Zhen Zhao E-mail:zzhao@sjtu.edu.cn
Supported by:
This work was supported by the National Natural Science Foundation of China (Grant No. 51475296).

Abstract

Abstract: 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.

The full text can be downloaded at https://link.springer.com/content/pdf/10.1007%2Fs40436-018-00245-y.pdf

Key words: Die roll, Duplex gear part, Sheet-bulk metal forming, Lateral extrusion, Material flow

Xiao-Long Sun, Xin-Cun Zhuang, Feng-Chun Yang, Zhen Zhao. Reduction of die roll height in duplex gears through a sheet-bulk metal forming method[J]. Advances in Manufacturing, 2019, 7(1): 42-51.

TrendMD

References

1. Sonsino CM, Ratzi R (2004) Warm powder compaction substitutes conventionally double pressed and double sintered synchroniser hubs. Powder Metall 47(4):352-357
2. Hayashi K (2006) Tool engineering for fineblanking and sheet metal forging complex work. J Jpn Soc Technol Plast 47(546):554
3. Kondo K, Maeda K (1972) Development of a new precision shearing process:opposed dies shearing process. In:Proceedings of the twelfth international machine tool design and research conference. Macmillan Education UK, pp 61-68
4. Kwak TS, Kim YJ, Bae WB (2002) Finite element analysis on the effect of die clearance on shear planes in fine blanking. J Mater Process Technol 130(11):462-468
5. Liu Y, Cheng T, Hua L et al (2017) Research on the effect of ultrasonic vibration on the roll-over during the fine blanking process. J Mech Sci Technol 31(2):835-843
6. Liu Y, Tang B, Hua L et al (2018) Investigation of a novel modified die design for fine-blanking process to reduce the dieroll size. J Mater Process Technol 260:30-37
7. Fan WF, Li JH (2009) An investigation on the damage of AISI-1045 and AISI-1025 steels in fine-blanking with negative clearance. Mater Sci Eng, A 499(1-2):248-251
8. Tanaka T, Hagihara S, Tadano Y et al (2011) Analysis of shear droop on cut surface of high-tensile-strength steel in fine-blanking process. Mater Trans 52(3):447-451
9. Huang X, Xiang H, Zhuang XC et al (2011) Improvement of dieroll quality in compound fine-blanking forming process. Adv Mater Res 337:236-241
10. Luo C, Chen Z, Zhou K et al (2017) A novel method to significantly decrease the die roll during fine-blanking process with verification by simulation and experiments. J Mater Process Technol 250:254-260
11. Gröbel D, Schulte R, Hildenbrand P et al (2016) Manufacturing of functional elements by sheet-bulk metal forming processes. Prod Eng 10(1):63-80
12. Merklein M, Allwood JM, Behrens BA et al (2012) Bulk forming of sheet metal. CIRP Ann Manuf Technol 61(2):725-745
13. Mori K, Nakano T (2016) State-of-the-art of plate forging in Japan. Prod Eng 10(1):81-91
14. Maeno T, Mori K, Hori A (2014) Application of load pulsation using servo press to plate forging of stainless steel parts. J Mater Process Technol 214(7):1379-1387
15. Hill R (1948) A theory of the yielding and plastic flow of anisotropic metals. Proceed R Soc Lond 193(1033):281-297
16. Sun X, Zhuang X, Zhao Z (2018) Investigation of anisotropy effects on sheet-bulk forming of duplex gear parts. Int J Mech Sci 140:51-59
17. Zhang DW, Ou H (2016) Relationship between friction parameters in a Coulomb-Tresca friction model for bulk metal forming. Tribol Int 95:13-18
18. Sofuoglu H, Rasty J (1999) On the measurement of friction coefficient utilizing the ring compression test. Tribol Int 32(6):327-335
19. Vierzigmann U, Koch J, Merklein M et al (2012) Material flow in sheet-bulk metal forming. Key Eng Mater 504-506:1035-1040

Reduction of die roll height in duplex gears through a sheet-bulk metal forming method

PDF

Knowledge

Abstract

Cite this article

share this article

References

Related Articles 0

Recommended Articles

Metrics

Comments