Skip to main content

Advertisement

SpringerLink
Log in

Investigation on metal flow and forming load of bi-metal gear hot forging process

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Aiming at the lightweight of gears, this article presents the hot forging process of a bi-metal gear fabricated by two metals of steel (tooth ring material) and aluminum alloy (core material). The process was studied by the finite element (FE) simulation and forming experiment. The FE model of the bi-metal gear forging process was established based on the symmetry of the gear and the structure of forging die by using the software Deform-3D. The hot forging experiment of the bi-metal gear was carried out to verify the accuracy of the FE simulation by the comparison of the metal flow behavior. Metal flow of three stages, namely upsetting, gap and tooth filling, and corner filling was analyzed in the hot forging process. Effects of three aspects including the gap between the core and ring, the height difference between the core and ring, and the ring thickness on the metal flow and forming load were investigated. The results of numerical simulation showed that different gaps and different height differences between the core and ring influence the relative flow of two metals and different ring thicknesses significantly influence the structure of the bi-metal gear; large gap and small height difference between the core and ring and small ring thickness can reduce the forming load.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Dobrzanski LA, Tanski T, Cizek L, Brytan Z (2007) Structure and properties of magnesium cast alloys. J Mater Process Technol 192:567–574

    Article  Google Scholar 

  2. Ohrn KE (2008) Aircraft energy use. In: Encyclopedia of energy engineering and technology. Taylor & Francis: Florida, pp. 24–30

  3. Rakhit AK (2000) Heat treatment of gears—a practical guide for engineers. ASM International, Materials Park, OH

    Google Scholar 

  4. Rongfeng S (2012) Design of skidding carriage gear mechanism based on lightweight. J Huazhong Univ Sci Technol (Nat Sci Ed) (S2):98–101 (in Chinese)

  5. Jing SK, Zhang H, Zhou JT, Song GH (2015) Optimum weight design of functionally graded material gears. Chin J Mech Eng 28(6):1186–1193 (in Chinese)

    Article  Google Scholar 

  6. Wadleigh AS (1993) Multi-metal composite gear/shaft—produced by consecutively forming, friction welding, reforming and friction welding, then machining three elements of dissimilar metals. US Patent No.5,492,264, December 21

  7. Igor K, Dejan M, Miroslav P, Dragiša V (2013) Preliminary investigation of cold forward, backward and radial extrusion of bi-metallic billets. J Technol Plast 38(2):134–142

    Google Scholar 

  8. Politis DJ, Lin J, Dean TA, Balint DS (2014) An investigation into the forging of bi-metal gears. J Mater Process Technol 214(11):2248–2260

    Article  Google Scholar 

  9. Yang X (2014) Investigation of formability and fracture in advanced metal forming process—bulk forging and sheet metal forming, PhD. thesis, Mechanical Engineering, The Ohio State University

  10. Bulent C, Robert C. G, B. Lynn F (2016) Hot hydroforging of lightweight bimaterial gears and hollow products. Paper presented at the 23rd IFHTSE Congress, Hyatt Regency Savannah, Georgia, April 20, 2016

  11. Robert C. G, Yang X, Bulent C, B. Lynn F (2016) Modeling of the heating sequences of lightweight bimaterial billets for hot forging. Paper presented at the 23rd IFHTSE Congress, Hyatt Regency Savannah, Georgia, April 21, 2016

  12. Alves ML, Rodrigues JMC, Martins PAF (2001) Cold forging of gears: experimental and theoretical investigation. Finite Elem Anal Des 37(6):549–558

    Article  MATH  Google Scholar 

  13. Khalilpourazary S, Dadvand A, Azdast T, Sadeghi MH (2011) Design and manufacturing of a straight bevel gear in hot precision forging process using finite volume method and CAD/CAE technology. Int J Adv Manuf Technol 56(1–4):87–95

    Article  Google Scholar 

  14. Dean TA (2000) The net-shape forming of gears. Mater Des 21(4):271–278

    Article  Google Scholar 

  15. Berviller L, Bigot R, Martin P (2006) Technological information concerning the integrated design of “net-shape” forged parts. Int J Adv Manuf Technol 31(3–4):247–257

    Article  Google Scholar 

  16. Baudouin C, Bigot R, Leleu S, Martin P (2008) Gear geometric control software: approach by entities. Int J Adv Manuf Technol 38(1–2):120–129

    Article  Google Scholar 

  17. Chen CC (2015) Grain-size effect on the forging formability of mini gears. Int J Adv Manuf Technol 79(5):863–871

    Article  Google Scholar 

  18. Pozuelo M, Carreno F, Cepeda-Jiménez CM, Ruano OA (2008) Effect of hot rolling on bonding characteristics and impact behavior of a laminated composite material based on UHCS-1.35 Pct C. Metall Mater Trans A 39(3):666–671

    Article  Google Scholar 

  19. Wang BY, Zuo B, Yang LY, Li Z, Zheng MN (2014) Forming process study and defect analysis of precision forging for the gear shafts of oil pumps. J Univ Sci Technol Beijing 36(8):1087–1093 (in Chinese)

  20. Zhang DW, Yang H, Sun ZC (2010) Finite element simulation of aluminum alloy cross valve forming by multi-way loading. Trans Nonferrous Metals Soc China 20(6):1059–1066

    Article  Google Scholar 

  21. Zhang W, Liu Y, Wang L, Liu B (2012) Numerical simulation and physical analysis for dynamic behaviors of P/M TiAl alloy in hot-packed forging process. Trans Nonferrous Metals Soc China 22(4):901–906

    Article  Google Scholar 

  22. Ji H, Liu J, Wang B, Zheng Z, Huang J, Hu Z (2015) Cross-wedge rolling of a 4Cr9Si2 hollow valve: explorative experiment and finite element simulation. Int J Adv Manuf Technol 77(1–4):15–26

    Article  Google Scholar 

  23. Sadeghi MH (2003) Gear forging: mathematical modeling and experimental validation. J Manuf Sci Eng 125(4):753–762

    Article  Google Scholar 

  24. Fang G, Zhou J, Duszczyk J (2008) Extrusion of 7075 aluminium alloy through double-pocket dies to manufacture a complex profile. J Mater Process Technol 209(6):3050–3059

    Article  Google Scholar 

  25. Wu HY, Lee SY, Wang JY (1998) Solid-state bonding of iron-based alloys, steel-brass, and aluminum alloys. J Mater Process Technol 75(1–3):173–179

    Article  Google Scholar 

  26. Hidetoshi S, Hiroyuki W, Toshiji M, Kenji H (2003) Low temperature diffusion bonding in a superplastic AZ31 magnesium alloy. Scr Mater 48(9):1249–1254

    Article  Google Scholar 

  27. Choi JC, Choi Y (1999) Precision forging of spur gears with inside relief. Int J Mach Tools Manuf 39(10):1575–1588

    Article  Google Scholar 

  28. Jinn-Jong S, Cheng-Hsien Y (2009) Preform and forging process designs based on geometrical features using 2D and 3D FEM simulations. Int J Adv Manuf Technol 44(3–4):244–254

    Google Scholar 

  29. Peng XK, Heness G, Yeung WY (1999) Effect of rolling temperature on interface and bond strength development of roll bonded copper/aluminum metal lamintes. J Mater Sci 34(2):227–281

    Article  Google Scholar 

  30. Aziz E, Chassapis C (2014) Comparative analysis of tooth-root strength using stress–strength interference (SSI) theory with FEM-based verification. Int J Interact Des Manuf 8(3):159–170

    Article  Google Scholar 

  31. Tanaka K, Kumagai M, Yoshida H (2006) Dissimilar joining of aluminum alloy and steel sheets by friction stir spot welding. J Jpn Inst Light Met 56(6):317–322

    Article  Google Scholar 

  32. Movahedi M, Madaah HR, Kokabi AH (2008) The influence of roll bonding parameters on the bond strength of Al-3003/Zn soldering sheets. Mater Sci Eng A 487(1–2):417–423

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. School of Mechanical Engineering, University of Science and Technology Beijing, Beijing, 100083, China

    Pengfei Wu, Baoyu Wang, J. Lin, Bin Zuo, Zhi Li & Jing Zhou

  2. Department of Mechanical Engineering, Imperial College London, London, SW7 2AZ, UK

    J. Lin

Authors
  1. Pengfei Wu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Baoyu Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. J. Lin
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Bin Zuo
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Zhi Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Jing Zhou
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Baoyu Wang.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Wu, P., Wang, B., Lin, J. et al. Investigation on metal flow and forming load of bi-metal gear hot forging process. Int J Adv Manuf Technol 88, 2835–2847 (2017). https://doi.org/10.1007/s00170-016-8973-x

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-016-8973-x

Keywords

Search

Navigation