Abstract
Numerical Analysis of a Six Stage Forging Process for Producing Hollow Flanged Parts from Tubular Blanks
Highlights
Stepped shafts can be produced with the use of different forming methods
The proposed method is based on the use of a sleeve moving opposite to the direction of the punch to produce a part with a flange of a relatively large diameter and height, when compared to the geometry of the tubular blank
Extrusion with the movable sleeve is a viable method for forming flanges directly on tubes and stepped preforms; the only failure mode that may occur in the initial stage of the process is local buckling of the workpiece wall, which may result in overlap or underfill;
Summary
Stepped shafts can be produced with the use of different forming methods. Pang et al studied the multistage forging process for a hollow axle shaft [1,2,3], in which a section of a tubular blank is upset to increase the wall thickness of the tube. Ji et al studied the fivestage cold extrusion process for shaft parts used in gearboxes [5] To this end, they combined open-die extrusion and upsetting, these two methods being often employed separately to produce parts. The proposed method is based on the use of a sleeve moving opposite to the direction of the punch to produce a part with a flange of a relatively large diameter and height, when compared to the geometry of the tubular blank. Threads are formed on the largest diameter step of the shaft
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