Abstract
A new cold rotary forging technology of the internal helical involute spline was presented based on an analysis of the structure of automotive starter guide cylinder. 3D rigid-plastic finite element model was employed. Billet deformation, Billet equivalent stress and forming load were investigated under the DEFORM 3D software environment, then the forming process parameters were applied in the forming trials, and the simulation results are conformed with the experimental results. The validity of 3D finite element simulation model has been verified. The research results show that the proposed cold rotary forging technology can be efficient in handling of the forming manufacturing problems of automobile starter guide cylinder with internal helical involute spline.
Highlights
Automotive starter guiding cylinder is the critical part of automotive starter transmission system, it works in a complex condition, and it has to meet the requirements for the excellent mechanical properties
3.1 Forming process design According to the final shape of automotive guide cylinder with helical involute spline, the forming process can be divided into ten stages: making billet, annealing, shot blasting, the saponification of phosphorus, forward extrusion, upsetting, backward extrusion cavity, machining guiding hole, the saponification of phosphorus, cold rotary forging internal helical involute spline
The primary aim of the experiment was to verify the feasibility of the proposed rotary forging technology. This experiment of the cold rotary forging process of automobile starter guide cylinder with the internal helical involute spline was conducted using YJ61-160A hydraulic testing press, which is an industrial metal extrusion hydraulic press made by Jiangdong machinery co., LTD
Summary
Automotive starter guiding cylinder is the critical part of automotive starter transmission system, it works in a complex condition, and it has to meet the requirements for the excellent mechanical properties. Most automotive starter guiding cylinders are manufactured by metal cutting, in which metal streamlines are cut off, lowering the mechanical properties. Base on the analysis of the structure of automotive starter guiding cylinder with internal helical involute spline, a new cold rotary forging technology was proposed. 1. The structure characteristics of the punch is mainly composed of the lower guiding part and the upper forming part, the lower guiding part is used to avoid material flow to the center, and the upper forming part is used to ensure the billet flow in a helical angle so as to form the internal helical involute spline in the process of extrusion. When the rotary forging process is completed, the punch leaves the lower die under the action of returned material device
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