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Research Papers

A Novel Cold Rotary Forging Method of Producing Multiple Racks Using One Set of Punch

[+] Author and Article Information
Xinghui Han

Hubei Key Laboratory of Advanced Technology
for Automotive Components,
Hubei Collaborative Innovation Center for
Automotive Components Technology,
Wuhan University of Technology,
Wuhan 430070, China
e-mail: hanxinghuihlp@126.com

Yaxiong Hu

Hubei Key Laboratory of Advanced Technology
for Automotive Components,
Hubei Collaborative Innovation Center for
Automotive Components Technology,
Wuhan University of Technology,
Wuhan 430070, China

Lin Hua

Hubei Key Laboratory of Advanced Technology
for Automotive Components,
Hubei Collaborative Innovation Center for
Automotive Components Technology,
Wuhan University of Technology,
Wuhan 430070, China
e-mail: hualin@whut.edu.cn

1Corresponding author.

Manuscript received June 29, 2017; final manuscript received January 7, 2018; published online June 1, 2018. Assoc. Editor: Gracious Ngaile.

J. Manuf. Sci. Eng 140(8), 081006 (Jun 01, 2018) (13 pages) Paper No: MANU-17-1401; doi: 10.1115/1.4039112 History: Received June 29, 2017; Revised January 07, 2018

When producing racks by cold rotary forging, the top punch and the rack teeth definitely intervene and thus the top punch has to be amended, which makes the technical designing processes difficult and complex (Han et al., 2016, “Cold Orbital Forging of Gear Rack,” Int. J. Mech. Sci., 117(10), pp. 227–242). In this study, a novel cold rotary forging method of producing racks is put forward to avoid the interventions between the top punch and the racks. Thus, the top punch need not be amended and the technical designing processes correspondingly become simple. In light of this presented method, a novel idea for cold rotary forging of producing multiple racks using one set of punch is motivated. The concrete researches are as follows: First, the mathematical models are developed and three kinds of key forging conditions in cold rotary forging of racks are calculated to avoid the interventions between the top punch and the racks. The first one is the condition that the top punch and the rack teeth do not intervene. The second one is the condition that the top punch and cylindrical surfaces of racks do not intervene. The third one is the condition that the top punch can be successfully constructed. On the basis of these three kinds of key forging conditions, the workpiece is optimized and the cold rotary forging processes of racks with constant and variable transmission ratio are examined using finite element (FE) simulations. The experimental researches are also conducted. The results show that for both racks with constant and variable transmission ratio, the obtained key forging conditions are effective and the presented cold rotary forging principles of producing multiple racks using one set of punch are feasible.

Copyright © 2018 by ASME
Topics: Forging
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Figures

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Fig. 1

Cold rotary forging principles of producing racks proposed by Han et al. [34] (Reprinted with permission from Elsevier @ 2016)

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Fig. 2

Cold rotary forging principles of producing multiple racks using one set of punch

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Fig. 3

Diagram of calculation condition that the top punch and the rack teeth do not intervene: (a) diagram of front view and (b) diagram of vertical view

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Fig. 4

Diagram of calculation condition that the top punch and the cylindrical surface of rack do not intervene

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Fig. 5

Range limit values that the top punch and the racks do not intervene in cold rotary forging: (a) range limit values that the top punch and the racks do not intervene based on L and (b) range limit values that the top punch and the racks do not intervene based on H

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Fig. 6

FE modeling in cold rotary forging of racks

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Fig. 7

Final geometries of the forged racks under different workpiece geometries through FE simulations: (a) final geometry of the forged rack using a complete cylinder workpiece, (b) final geometry of the forged rack using a cylinder workpiece with a groove, and (c) final geometry of the forged rack using the optimized workpiece

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Fig. 8

Geometry evolutions of cold rotary forged rack under different moments when H > 0: (a) the bottom punch feeds axially and (b) the bottom punch stops the axial feeding

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Fig. 9

Geometry evolutions of cold rotary forged rack under different moments when H < 0: (a) the bottom punch feeds axially and (b) the bottom punch stops the axial feeding

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Fig. 10

Geometry evolutions of cold rotary forged rack under different moments when H = 0: (a) the bottom punch feeds axially and (b) the bottom punch stops the axial feeding

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Fig. 11

Cold rotary forged rack in the simulation and experiments under the optimized workpiece geometry: (a) cold rotary forged rack in the simulation and (b) cold rotary forged rack in the experiments

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Fig. 12

One line on the tooth plane A of the experimental cold rotary forged rack

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Fig. 13

Teeth profile of rack with variable transmission ratio

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Fig. 14

Geometry model of rack with variable transmission ratio

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Fig. 15

Geometry evolutions of cold rotary forged rack with variable transmission ratio under different moments: (a) 0 s, (b) 1.02 s, (c) 1.35 s, (d) 1.68 s, and (e) 3.0 s

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Fig. 16

Strain evolutions of cold rotary forged rack with variable transmission ratio under different moments: (a) 0 s, (b) 1.02 s, (c) 1.35 s, (d) 1.68 s, and (e) 3.0 s

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