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Research Papers

Experimental and Numerical Simulation Study of Simultaneous Toothing of Spur Gears by Press-Rolling Process

[+] Author and Article Information
Liviu Nistor

Department of Materials
Science and Engineering,
Technical University,
103-105 Bwd. Muncii,
Cluj-Napoca 400641, Romania
e-mail: Liviu.Nistor@ipm.utcluj.ro

Adriana Neag

Department of Materials
Science and Engineering,
Technical University,
103-105 Bwd. Muncii,
Cluj-Napoca 400641, Romania;
M.S.E. Department (G03),
Technical University,
103-105 Bwd. Muncii,
Cluj-Napoca 400641, Romania;
e-mail: adriana.neag@ipm.utcluj.ro

Ionut Marian

Department of Materials
Science and Engineering,
Technical University,
103-105 Bwd. Muncii,
Cluj-Napoca 400641, Romania
e-mail: marianionut78@yahoo.com

Dan Frunza

Department of Materials
Science and Engineering,
Technical University,
103-105 Bwd. Muncii,
Cluj-Napoca 400641, Romania
e-mail: Dan.Frunza@ipm.utcluj.ro

1Corresponding author.

Manuscript received January 21, 2016; final manuscript received August 10, 2016; published online September 29, 2016. Assoc. Editor: Yannis Korkolis.

J. Manuf. Sci. Eng 138(12), 121015 (Sep 29, 2016) (7 pages) Paper No: MANU-16-1055; doi: 10.1115/1.4034493 History: Received January 21, 2016; Revised August 10, 2016

In this paper, the cold simultaneous toothing of spur gears has been investigated. This method can be described as a press-rolling process. The influence of gear geometry such as teeth number and the deformation mechanism was investigated by 3D finite-element analysis using forge® software in terms of teeth forming and forming loads evolution. Based on these simulations, the experimental investigations were carried out to obtain a spur gear form with the good quality, using several billet dimensions. The experimental trials and simulations conducted for the spur gear (z = 23 teeth and m = 1.5 mm) showed premises to continuous flow lines formation at the base of the teeth. The maximum pressing force results from the numerical simulation agree with the experimental maximum force recorded.

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Figures

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Fig. 1

The geometrical solid model used to the spur gear formation by simultaneous toothing

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Fig. 2

(a) The experimental working tool and (b) some of the finished products

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Fig. 3

Geometrical parameters of the deformation zone

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Fig. 4

Evolution of deformation along the length of the roll–metal contact arc

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Fig. 5

Schematic representation of the forces system in the deformation zone

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Fig. 6

Schematic representation of the stresses system in a small element of material

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Fig. 7

Sensors position in the deformation zone

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Fig. 8

Flow material speed measured by numerical sensors along the side of the tooth

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Fig. 9

Distribution of equivalent strain (a) and von Mises stress (b), in the deformation zone—the final state process

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Fig. 10

Distribution of equivalent strain (a, c) and von Mises stress (b, d) in different cross sections slice relatively to the pressing direction of the punch; successive evolution from the entry to the exit plan, (up-intermediate; down-final state)

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Fig. 11

Experimental and simulated height tooth evolution along the deformation zone

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Fig. 12

Pressing force evolution considering different billet diameters for the deformation regimes

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