Abstract
Abstract The manufacturing of the gear profile by Metal Forming is widely used in industry due to its quality and production capability. Direct cold extrusion has this characteristic and with support of peripheral technologies allows the development of asymmetric parts with complex geometry and near net shape. These resources, added with the great experience of a Brazilian forging company with strong presence in the cold forging market, allowed to develop a cold extrusion process to produce spur gears using the low carbon steel alloy described as SAE 10B22. The goal of this study was to develop the whole process, precision tooling project and manufacture as well as the experimental availability of the process. The tools were manufactured with high speed steel AISI M2 having a hardness in a range from 61 up to 63 HRc. The shrink rings were manufactured using steels with more toughness, such as S1 and H13. The application of shrink rings for the prestressing of tooling was evaluated using two different methods. The first one is using conventional shrink rings with tool steel, while the second is the stripwinding concept developed by the company STRECON.
Highlights
In recent years, the automotive sector has presented several proposals for quality improvement and efficiency increase applied to topics such as fuel consumption and transmission systems
This article illustrates the comparative results between the dimension of gears produced by cold extrusion in a conventional double shrink ring tooling and a high strength shrink ring system developed by the STRECON Company
The residual stresses and tool elastic deformation, which applies a plastic deformation on a forged product, are some of the main points that affect the gear accuracy grade of the pinion
Summary
The automotive sector has presented several proposals for quality improvement and efficiency increase applied to topics such as fuel consumption and transmission systems. The car manufactures have the challenging mission to reduce weight and to increase the component strength in order to meet the current strict requirements of the automotive market. It is said that products may obtain greater resistance through forging technology. Cold forging has become a technology commonly used. The technological development and quality control from the beginning of the process up to the final product must be observed to obtain such progress in precision cold forging, which is connected with high quality materials and cutting edge techniques. Some results obtained through precision cold forging and assistive technologies are presented
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