Abstract
A simulation based approach has been proposed to form hollow gear of EN-10130 steel by a tube hydroforming process. Manufacturing of the gear teeth is analyzed by forming limit diagram (FLD) and strain non-uniformity index (SNI) method. In this approach, pressure and compression rate are controlled independently to produce defect free product. FLD and SNI method showed good agreement in predicting the failure of the part. Ideal parameters have been proposed to get defect free part. It has been evaluated that the gear formed can be readily used for low torque transmission application.
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