Recent developments in the extrusion of helical gears
With an improved die, a method for manufacturing gears by means of tube extrusion has been developed to a stage where, without noticeable wear of the die, 40,000 workpieces can be manufactured. The paper presents a numerical analysis of the stresses and deflection of the die, offering also a compari...
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Published in | International journal of machine tools & manufacture Vol. 33; no. 4; pp. 599 - 614 |
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Main Authors | , , |
Format | Journal Article |
Language | English |
Published |
Oxford
Elsevier Ltd
01.08.1993
Elsevier |
Subjects | |
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Abstract | With an improved die, a method for manufacturing gears by means of tube extrusion has been developed to a stage where, without noticeable wear of the die, 40,000 workpieces can be manufactured. The paper presents a numerical analysis of the stresses and deflection of the die, offering also a comparison between the modified and the conventional symmetric orifice. Based on the results obtained and using recent work on crack prediction for extrusion dies, the area most prone to rupture is determined. Moreover, a concept for the precorrection of the die is offered to improve the tooth quality of the gears. |
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AbstractList | With an improved die, a method for manufacturing gears by means of tube extrusion has been developed to a stage where, without noticeable wear of the die, 40,000 workpieces can be manufactured. The paper presents a numerical analysis of the stresses and deflection of the die, offering also a comparison between the modified and the conventional symmetric orifice. Based on the results obtained and using recent work on crack prediction for extrusion dies, the area most prone to rupture is determined. Moreover, a concept for the precorrection of the die is offered to improve the tooth quality of the gears. With an improved die, a method for manufacturing gears by means of tube extrusion has been developed to a stage where, without noticeable wear of the die, 40,000 workpieces can be manufactured. Presents a numerical analysis of the stresses and deflection of the die, offering a comparison between the modified and the conventional symmetric orifice. Based on the results obtained and using recent work on crack prediction for extrusion dies, the area most prone to rupture is determined. A concept for the precorrection of the die is offered to improve the tooth quality of the gears. (Original abstract-amended) |
Author | Fan, J.A. Seibert, D. König, W. |
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Keywords | Finite element method Numerical analysis Simulation Helical gear Prediction Rupture Extrusion Forming Stress strain Gear |
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References | Gegel, Malas, Gunasekera, Morgan, Doraivelu (BIB7) 1984 Roll, Tekkaya, Roll, Tekkaya (BIB14) 1985; 32 Lange (BIB21) 1985; 27 Yoshida, Wanheim (BIB11) 1988; 37 Krämer (BIB19) 1979 Geiger (BIB22) 1991; 40 Kobayashi, Oh, Altan (BIB15) 1989 Haberling, Schruff (BIB16) 1985; 11 Jütte (BIB17) 1985 (BIB25) 1978 Schmoeckel (BIB6) 1966 Han, Yang (BIB9) 1988; 30 Reiss (BIB24) 1988; 130 König, Koll (BIB18) 1990 Timoshenko, Goodier (BIB20) 1985 Dohmann, Laufer, Dohmann, Laufer (BIB12) 1989; 40 Lange, Gerhardt, Hoffmann, Kang (BIB13) 1990 König (BIB2) 1990 Geiger, Hänsel, Rebhan (BIB23) 1991 Lange (BIB1) 1984 Yang, Lee, Yoon (BIB8) 1989; 31 Pehle (BIB10) 1983 Bartsch (BIB3) 1989 Samanta (BIB4) 1976 Koll (BIB5) 1990 Lange (10.1016/0890-6955(93)90095-C_BIB1) 1984 Bartsch (10.1016/0890-6955(93)90095-C_BIB3) 1989 Reiss (10.1016/0890-6955(93)90095-C_BIB24) 1988; 130 Han (10.1016/0890-6955(93)90095-C_BIB9) 1988; 30 Timoshenko (10.1016/0890-6955(93)90095-C_BIB20) 1985 Roll (10.1016/0890-6955(93)90095-C_BIB14_2) 1985; 32 Koll (10.1016/0890-6955(93)90095-C_BIB5) 1990 Yoshida (10.1016/0890-6955(93)90095-C_BIB11) 1988; 37 Lange (10.1016/0890-6955(93)90095-C_BIB13) 1990 Kobayashi (10.1016/0890-6955(93)90095-C_BIB15) 1989 Haberling (10.1016/0890-6955(93)90095-C_BIB16) 1985; 11 König (10.1016/0890-6955(93)90095-C_BIB2) 1990 Dohmann (10.1016/0890-6955(93)90095-C_BIB12_1) 1989; 40 König (10.1016/0890-6955(93)90095-C_BIB18) 1990 Roll (10.1016/0890-6955(93)90095-C_BIB14_1) 1985; 32 Jütte (10.1016/0890-6955(93)90095-C_BIB17) 1985 Schmoeckel (10.1016/0890-6955(93)90095-C_BIB6) 1966 Gegel (10.1016/0890-6955(93)90095-C_BIB7) 1984 Samanta (10.1016/0890-6955(93)90095-C_BIB4) 1976 Dohmann (10.1016/0890-6955(93)90095-C_BIB12_2) 1989; 40 Lange (10.1016/0890-6955(93)90095-C_BIB21) 1985; 27 Yang (10.1016/0890-6955(93)90095-C_BIB8) 1989; 31 Krämer (10.1016/0890-6955(93)90095-C_BIB19) 1979 Geiger (10.1016/0890-6955(93)90095-C_BIB22) 1991; 40 Pehle (10.1016/0890-6955(93)90095-C_BIB10) 1983 (10.1016/0890-6955(93)90095-C_BIB25) 1978 Geiger (10.1016/0890-6955(93)90095-C_BIB23) 1991 |
References_xml | – start-page: 8-1 ff year: 1984 ident: BIB7 article-title: Computer-aided design of extrusion dies by metal-flow simulation publication-title: AGARD Lecture Series No. 137 contributor: fullname: Doraivelu – start-page: 233 year: 1990 ident: BIB13 article-title: Prozeßsimulation und Werkzeugverformung bei dreidimensionalen Umformvorgängen publication-title: Präzisionsumformtechnik contributor: fullname: Kang – volume: 32 start-page: 284 year: 1985 ident: BIB14 article-title: Prozeßsimulation in der Umformtechnik mit der Methode der Finiten Elemente—Stand und Entwicklungstendenzen—part I publication-title: Blech Rohre Profile contributor: fullname: Tekkaya – volume: 30 start-page: 13 year: 1988 end-page: 30 ident: BIB9 article-title: Further investigation into extrusion of trocoidal gear sections considering three-dimensional plastic flow publication-title: Int. J. mech. Sci. contributor: fullname: Yang – volume: 130 start-page: 56 year: 1988 ident: BIB24 article-title: Bruch und Verschleiß von Umformwerkzeugen publication-title: VDI-Z contributor: fullname: Reiss – year: 1966 ident: BIB6 article-title: Untersuchungen über die Werkzeuggestaltung beim Hohl-Vorwärts-Fließpressen von Stahl und Nichteisenmetallen publication-title: Bericht aus dem Institut für Umformtechnik, No. 4 contributor: fullname: Schmoeckel – volume: 27 start-page: 169 year: 1985 end-page: 175 ident: BIB21 article-title: On the stress distribution in prestressed extrusion dies under non-uniform distribution of internal pressure publication-title: Int. J. mech. 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Neuere Entwicklungen in der Massivumformung contributor: fullname: Bartsch – start-page: 193 year: 1990 ident: BIB18 article-title: Kaltflißpressen von Bauteilen mit Verzahnungen publication-title: Präzisionsumformtechnik contributor: fullname: Koll – year: 1990 ident: BIB2 publication-title: Fertigungsverfahren, Vol. 4: Massivumformung contributor: fullname: König – volume: 31 start-page: 145 year: 1989 end-page: 156 ident: BIB8 article-title: Finite element analysis of steady-state three-dimensional extrusion of sections through curved dies publication-title: Int. J. mech. Sci. contributor: fullname: Yoon – year: 1989 ident: BIB15 article-title: Metal Forming and the Finite-Element Method publication-title: Oxford Series On Advanced Manufacturing contributor: fullname: Altan – volume: 37 start-page: 221 year: 1988 end-page: 224 ident: BIB11 article-title: The method for the 3-D strain and strain rate analyses in visioplasticity publication-title: Ann. CIRP contributor: fullname: Wanheim – volume: 40 start-page: 405 year: 1989 end-page: 409 ident: BIB12 article-title: Kaltfließpressen von Schrägverzahnungen Part 1 publication-title: Draht contributor: fullname: Laufer – year: 1983 ident: BIB10 article-title: Untersuchungen zu Grundlagen und Genauigkeit visioplastischer Berechnungen publication-title: Dissertation contributor: fullname: Pehle – year: 1990 ident: BIB5 article-title: Kaltfließpressen von Bauteilen mit Verzahnungen publication-title: Dissertation contributor: fullname: Koll – volume: 30 start-page: 13 year: 1988 ident: 10.1016/0890-6955(93)90095-C_BIB9 article-title: Further investigation into extrusion of trocoidal gear sections considering three-dimensional plastic flow publication-title: Int. J. mech. Sci. doi: 10.1016/0020-7403(88)90031-8 contributor: fullname: Han – start-page: 233 year: 1990 ident: 10.1016/0890-6955(93)90095-C_BIB13 article-title: Prozeßsimulation und Werkzeugverformung bei dreidimensionalen Umformvorgängen contributor: fullname: Lange – year: 1990 ident: 10.1016/0890-6955(93)90095-C_BIB2 contributor: fullname: König – year: 1985 ident: 10.1016/0890-6955(93)90095-C_BIB20 contributor: fullname: Timoshenko – volume: 40 start-page: 484 year: 1989 ident: 10.1016/0890-6955(93)90095-C_BIB12_2 article-title: Kaltfließpressen von Schrägverzahnungen Part II publication-title: Draht contributor: fullname: Dohmann – year: 1966 ident: 10.1016/0890-6955(93)90095-C_BIB6 article-title: Untersuchungen über die Werkzeuggestaltung beim Hohl-Vorwärts-Fließpressen von Stahl und Nichteisenmetallen contributor: fullname: Schmoeckel – year: 1989 ident: 10.1016/0890-6955(93)90095-C_BIB15 article-title: Metal Forming and the Finite-Element Method contributor: fullname: Kobayashi – year: 1983 ident: 10.1016/0890-6955(93)90095-C_BIB10 article-title: Untersuchungen zu Grundlagen und Genauigkeit visioplastischer Berechnungen contributor: fullname: Pehle – volume: 31 start-page: 145 year: 1989 ident: 10.1016/0890-6955(93)90095-C_BIB8 article-title: Finite element analysis of steady-state three-dimensional extrusion of sections through curved dies publication-title: Int. J. mech. Sci. doi: 10.1016/0020-7403(89)90075-1 contributor: fullname: Yang – volume: 32 start-page: 284 year: 1985 ident: 10.1016/0890-6955(93)90095-C_BIB14_1 article-title: Prozeßsimulation in der Umformtechnik mit der Methode der Finiten Elemente—Stand und Entwicklungstendenzen—part I publication-title: Blech Rohre Profile contributor: fullname: Roll – year: 1991 ident: 10.1016/0890-6955(93)90095-C_BIB23 article-title: Improving the fatigue resistance of cold forging tools by FE-simulation and computer aided die shape optimization contributor: fullname: Geiger – year: 1990 ident: 10.1016/0890-6955(93)90095-C_BIB5 article-title: Kaltfließpressen von Bauteilen mit Verzahnungen contributor: fullname: Koll – volume: 130 start-page: 56 year: 1988 ident: 10.1016/0890-6955(93)90095-C_BIB24 article-title: Bruch und Verschleiß von Umformwerkzeugen publication-title: VDI-Z contributor: fullname: Reiss – year: 1978 ident: 10.1016/0890-6955(93)90095-C_BIB25 publication-title: Toleranzen für Stirnradverzahungen – volume: 11 start-page: 99 year: 1985 ident: 10.1016/0890-6955(93)90095-C_BIB16 article-title: Zusammenstellung der Eigenschaften und Werkstroffkenngrößen des Schnellarbeitsstahles S 6-5-2 publication-title: Thyssen Edelst. Techn. Ber. contributor: fullname: Haberling – volume: 40 start-page: 405 year: 1989 ident: 10.1016/0890-6955(93)90095-C_BIB12_1 article-title: Kaltfließpressen von Schrägverzahnungen Part 1 publication-title: Draht contributor: fullname: Dohmann – year: 1984 ident: 10.1016/0890-6955(93)90095-C_BIB1 contributor: fullname: Lange – start-page: 199 year: 1976 ident: 10.1016/0890-6955(93)90095-C_BIB4 article-title: Helical gears: a novel method of manufacturing contributor: fullname: Samanta – volume: 40 start-page: 303 year: 1991 ident: 10.1016/0890-6955(93)90095-C_BIB22 article-title: Facture-mechanics analysis of extrusion dies publication-title: Ann. CIRP doi: 10.1016/S0007-8506(07)61992-1 contributor: fullname: Geiger – year: 1979 ident: 10.1016/0890-6955(93)90095-C_BIB19 article-title: Beitrag zur beanspruchungsgerechten Auslegung von rotationssymmetrischen Fließpreßmatrizen contributor: fullname: Krämer – year: 1985 ident: 10.1016/0890-6955(93)90095-C_BIB17 article-title: Beitrag zum Präzisionsumformen von Stirnradverzahnungen contributor: fullname: Jütte – start-page: 193 year: 1990 ident: 10.1016/0890-6955(93)90095-C_BIB18 article-title: Kaltflißpressen von Bauteilen mit Verzahnungen contributor: fullname: König – volume: 37 start-page: 221 year: 1988 ident: 10.1016/0890-6955(93)90095-C_BIB11 article-title: The method for the 3-D strain and strain rate analyses in visioplasticity publication-title: Ann. CIRP doi: 10.1016/S0007-8506(07)61622-9 contributor: fullname: Yoshida – volume: 27 start-page: 169 year: 1985 ident: 10.1016/0890-6955(93)90095-C_BIB21 article-title: On the stress distribution in prestressed extrusion dies under non-uniform distribution of internal pressure publication-title: Int. J. mech. Sci. doi: 10.1016/0020-7403(85)90057-8 contributor: fullname: Lange – year: 1989 ident: 10.1016/0890-6955(93)90095-C_BIB3 article-title: Anforderungen an umformtechnische Zahnradfertigungsverfahren aus der Sicht des Getriebebaus contributor: fullname: Bartsch – start-page: 8-1 ff year: 1984 ident: 10.1016/0890-6955(93)90095-C_BIB7 article-title: Computer-aided design of extrusion dies by metal-flow simulation contributor: fullname: Gegel – volume: 32 start-page: 327 year: 1985 ident: 10.1016/0890-6955(93)90095-C_BIB14_2 article-title: Prozeßsimulation in der Umformtechnik mit der Methode der Finiten Elemente—Stand und Entwicklungstendenzen—part II publication-title: Blech Rohre Profile contributor: fullname: Roll |
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Title | Recent developments in the extrusion of helical gears |
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