Abstract
A two-stage cold forging process was proposed to manufacture a drive shaft with an internal spline and spur gear geometries, and this process was mainly composed of a forward extrusion for preform and a forward-backward extrusion for the drive shaft. In the process design, the preform was designed using a volume apportioning scheme from the required target shape, thereafter, the initial round billet was outlined. AISI 1035 carbon steel was selected as the raw material, and a spheroidizing heat treatment was adopted. Using the raw and spheroidizing annealed workpieces, uni-axial tensile and compression tests were carried out to evaluate the effect of the heat treatment and to measure the mechanical properties. Finite element simulations were sequentially performed to assure the suitability of the proposed process design. Considering the results from the process design and the numerical simulations, the related tool components were prepared and applied to a series of experimental investigations. The preform and the drive shaft fabricated by the two-stage cold forging experiments were compared with the required target and the numerically predicted configurations. The results indicated that the two-stage cold forging process proposed in this study could be well applied to the production of the drive shaft with an internal spline and spur gear structures.
Highlights
As mechanical joints, gears and splines are mainly used for transmitting rotational motion and torque from a power source to other functional members and structures
The drive shaft in this study has a distinct feature in that the internal spline and the spur gear are conjoined into one piece, and it is in charge of the key functions of transmitting rotational power and torque obtained from a prime mover into the inner actuator in a hydraulic pump for general industrial machinery
Based on the results of the process design proposed in this study and a series of the tool structures used in the numerical simulations, it was verified that the preform and the drive shaft can be structures used in the numerical simulations, it was verified that the preform and the drive shaft can properly manufactured by the forward extrusion process and the forward-backward extrusion operation, be properly manufactured by the forward extrusion process and the forward-backward extrusion along with the tool components and the 600 Tonf hydraulic press
Summary
Gears and splines are mainly used for transmitting rotational motion and torque from a power source to other functional members and structures. The spline formed at the longitudinally expanded end along the shaft of the power source is connected to the internal spline configured at the end of the other shaft member on the same axis, so the rotational motion and the torque can be directly transferred to the other mechanical component [1]. With regard to the manufacturing method used for the spline and the gear, forging processes and machining sequences, including material removal are widely adopted. These components as the mechanical-structural metal member are basically required to have high strength and high structural stiffness against the torque, as well as high wear-resistance and durability characteristics. In order to satisfy these requirements, a series of inherent defects such as void and micro-crack, as well as residual stress derived from plastic deformation of the workpiece, should be eliminated or minimized [4]; the metal forging process is more widely recommended than material removal and machining as an acceptable production scheme [5,6]
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