Abstract
The formation of hot forging-upsetting finishing-radial extrusion (HF-UF-RE) compound into conjunction gears is an innovative process. This study describes the most existing manufacturing methods of the conjunction gear. Simulation and experimental research is conducted using this new method. First, a type of extrusion die is designed to form the back taper. The finite element models of hot forging, finishing, and radial extrusion are then established to estimate the feasibility of formation process of this compound. This study analyzes the law of metal flow in the process, the influence of the finishing parameters on the surface quality, and the distribution of stress and strain in extrusion. Metal flows from the tooth tip to the tooth bottom during the finishing process. The finishing qualities of different finishing parameters have been discussed. Local plastic deformation occurs at the tooth bottom during radial extrusion. The gears formed by each process are consistent with the designed shapes and meet the application requirements of the conjunction gear. HF-UF-RE is feasible for the formation process of conjunction gears.
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