Abstract
Parametric investigations related to shoulder angle on tool geometry for a combined cold extrusion of a drive shaft, which consisted of spur gear and internal spline structures, were conducted through three-dimensional FE (finite element) simulations. The drive shaft was required to be about 92.00 mm for the face width of the top land on the spur gear part and roughly 22.70 mm for the groove depth of the internal spline section. AISI 1035 carbon steel material with a diameter of 50.00 mm and a length of 121.00 mm was spheroidized and annealed, then used as the initial billet material. A preform as an intermediate workpiece was adopted to avoid the excessive accumulation of plastic deformation during the combined cold extrusion. Accordingly, the cold forging process involves two extrusion operations such as a forward extrusion and a combined extrusion for the preform and the drive shaft. As the main geometric parameters influencing the dimensional quality and the deformed configuration of the final product, the two shoulder angles of θ1 and θ2 for the preform forging and the combined extrusion were both considered to be appropriate at 30°, 45°, and 60°, respectively. Using nine geometric parameter combinations, three-dimensional finite element simulations were performed, and these were used to evaluate the deformed features and the geometric compatibilities on the spur gear structure and the internal spline feature. Based on these comparative evaluations using the numerically simulated results, it is shown that the dimensional requirements of the target shape can be satisfied with the shoulder angle combination of (45°, 45°) for (θ1, θ2).
Highlights
In various cold working processes, a combined forging is classified as an operation that merges similar or different sequences together into a single procedure [1,2,3]; it is aimed at process simplification and lead-time reduction by curtailing the number of processes required to obtain a forged component with a complicated shape [4,5]
The parametric investigations with regards to both shoulder angles of θ1 and θ2 on on the extrusion dies were conducted as shown in Figures 7 and 9, respectively; it was the extrusion dies were conducted as shown in Figures 7 and 9, respectively; it was observed observed that the deformed geometries are numerically well-simulated and the effective stress and that the deformed geometries are numerically well-simulated and the effective stress and strain are strain are appropriately distributed
Study, aa drive drive shaft shaft that that two two distinctive distinctive features features such such as as the the spur spur gear gear feature feature and and the the internal spline geometry were merged into a single shaft was introduced
Summary
In various cold working processes, a combined forging is classified as an operation that merges similar or different sequences together into a single procedure [1,2,3]; it is aimed at process simplification and lead-time reduction by curtailing the number of processes required to obtain a forged component with a complicated shape [4,5]. The spur gear has a unique configuration of sixteen tooth profiles, while the internal spline has a distinctive shape of an irregular hexadecagonal cross-sectioned deep groove. Considering these external features of the drive shaft used for the hydraulic pump, it can be envisaged that it would be difficult to directly extrude the initial cylindrical workpiece to the final configuration without an excessive accumulation of plastic deformation. A series of geometric comparisons between the designed drive shaft and the simulated results were conducted with respect to the deep groove within the internal spline having the irregular hexadecagonal cross-section, as well as the sixteen tooth profiles of the spur gear. The results showed that preform forging and combined extrusion could successfully be adopted to visualize the drive shaft used for the hydraulic pumps with a good consistency regarding the dimensional requirements
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