Green manufacturing process for helical pinion gear using cold extrusion process

Abstract

In this research, a cold extrusion process that can replace conventional machining process is developed for sustainable production. The cold extrusion method requires an analytical design process to assure desired dimensional accuracy of the final product. Therefore, the design must consider the material flow during the process in order to avoid product defects such as folding and underfilling. The forming load and material flow were analyzed using a commercial finite element code, DEFORM3D. To improve the dimensional accuracy, the shape of die and initial billet were designed using minimum distance analysis via FE simulation. Also the developed process included ejection for improving dimensional accuracy, and it was verified by a gear accuracy test. Isothermal annealing and spheroidizing were applied for increasing the formability of high strength workpiece. Finally a helical pinion gear was manufactured using the developed process and the product was compared to the simulation results. In conclusion, the developed process is a scrap reducing and energy saving method for manufacturing extrusion product with high dimensional accuracy.