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TECHNICAL PAPERS

Determination of a Major Design Parameter for Forward Extrusion of Spur Gears

[+] Author and Article Information
Jong-Ho Song, Yong-Taek Im

Computer Aided Materials Processing Laboratory, Department of Mechanical Engineering, ME3227, Korea Advanced Institute of Science and Technology, 373-1 Guseong-dong, Yuseong-gu, Daejeon 305-701, South Korea

J. Manuf. Sci. Eng 126(2), 255-263 (Jul 08, 2004) (9 pages) doi:10.1115/1.1688379 History: Received September 01, 2002; Revised October 01, 2003; Online July 08, 2004
Copyright © 2004 by ASME
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References

Figures

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Comparison of the cross-sectional grid distortions between FE simulations and experiments available in the literature: (a) extrusion without a mandrel 10 and (b) extrusion with a mandrel 11
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The variation of (a) the ratio of total teeth area to gear area and (b) predicted forming loads according to teeth number
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The overall deformed shapes and distributions of the effective strain in cold forward extrusion of a spur gear with the (a) 7 and (b) 18 teeth number
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The predicted distributions of the effective strain in forward extrusion with entrance angles of (a) 30°, (b) 45°, and (c) 60°
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Contour plots of the velocity distribution in the z direction for various shear friction factors of (a) 0.1, (b) 0.2, (c) 0.3, and (d) 0.6
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Comparison of deformed shapes of the workpiece obtained from FE simulations with variations of the billet radius
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Distributions of the effective strain obtained from FE simulations with variations of the mandrel radius of (a) 20 mm, (b) 30 mm, and (c) 35 mm
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FE simulation results for complete filling of a tooth according to the geometric ratio of a spur gear: (a) the area ratio between the total teeth and a gear and (b) the area ratio between a gear and root
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Relationship between the determined design parameter ERr/o and complete filling status of a tooth
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Definition of the geometry of a spur gear and its graphical representation
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The standard design geometry of the die for cold forward extrusion of a spur gear with a mandrel
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The investigated process variables in cold forward extrusion of a spur gear

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