Abstract
The research subjects of current investigations at the Institute for Metal Forming Technology (IFU) Stuttgart include the manufacture of face gearings. Usually, gearings are produced by means of a coining process, which causes high process forces that considerably restrict the geometry of the teeth in terms of the height-to-width ratio. In order to avoid these problems, a new forming process has been developed. This technology offers significant advantages, such as the reduction of process forces and the ability to manufacture the required tall and acuminate tooth elements through a cold-forming process. This paper describes the design and functionality of the novel pin-to-gear forming process. In this paper, the operating principle of the method is presented first of all. The new pin-to-gear process is then compared to conventional coining and the free-divided-flow (FDF) process developed at IFU Stuttgart in 2018. This examination takes the form of a numerical simulation using DEFORM-2D software. To investigate the influence of preform parameters on the form filling of the tooth cavities, parameter studies in design and geometry are conducted. Process limits regarding geometric constraints are presented alongside possibilities for increasing process reliability. Through this investigation, the potential and opportunities of the innovative pin-to-gear forming process will be illustrated.
Highlights
Cold forming offers various advantages, such as high strength, accuracy, surface quality, and optimum grain flow for an extended service life and cost-effective production
This paper describes the process principle of the new pin-to-gear process and compares it with familiar FDF processes before presenting a parameter study to determine preform parameters of the pin-to-gear process
Using the conventional coining processes, the difficult-to-shape elements are filled until the end of the process is reached
Summary
Cold forming offers various advantages, such as high strength, accuracy, surface quality, and optimum grain flow for an extended service life and cost-effective production. To fully exploit the process-specific advantages while considering ambitious geometries, several new forming strategies have been developed One of these innovative processes is the free-divided-flow (FDF) process developed at IFU Stuttgart. An additional process for manufacturing face gears was developed recently at the IFU Stuttgart that involves material predistribution: the “pin-to-gear” process. This process is based on the same operating principle as the FDF process. The pinto-gear process requires a different material preform This new material predistribution enables production of accurate face gears in a two-stage coining process with lower process forces compared to the FDF process or conventional coining. This paper describes the process principle of the new pin-to-gear process and compares it with familiar FDF processes before presenting a parameter study to determine preform parameters of the pin-to-gear process
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