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A precision sizing method for cold extruded sun gear with internal-external tooth shapes

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Abstract

Due to the complex metal flow in the cold extrusion of sun gear, the teeth accuracy of formed sun gear is poor. In order to improve the accuracy of extruded sun gear, a precision sizing method was proposed in this study. Finite element simulation for predicting tooth deviations of finished sun gear was performed using DEFORM, and the influences of key process parameters such as the sizing amount of external gear, interference value of internal spline, die bearing length, and friction factor on gear deviations were examined. The simulation results reveal that the accuracy of extruded sun gear can be significantly improved with the sizing amount of external gear as 0.2 mm, spline interference value as 0.10 mm, die bearing length as 19 mm, and friction factor as 0.12. Finally, experimental investigation was carried out by the developed precision shaping method. The experimental results show that the profile accuracy of external gear after cold shaping operation is the seventh, the gear lead accuracy is the eighth, and the total M value deviation of internal spline is reduced to 0.07 mm, which proves the feasibility of precision sizing method and the correctness of numerical simulation results.

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Availability of data and materials

All data, models, and code generated or used during the study appear in the submitted article.

Abbreviations

f α :

Single profile deviation of external gear

F α :

Total profile deviation of external gear

F β :

Total helix deviation of external gear

Q :

Accuracy grade of external gear

M :

M value of internal spline

F M :

Total M value deviation of internal spline

T L :

Left tooth thickness of external gear

T R :

Right tooth thickness of external gear

ΔL 1 :

Sizing amount of external gear

ΔL 2 :

Interference value of internal spline

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Funding

This research was financially supported by the National Key Research and Development Program of China (No.2018YFB1106504) and Postdoctoral Science Foundation of Chongqing Natural Science Foundation (No. cstc2020jcyj-bshX0006).

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Authors and Affiliations

  1. College of Materials Science and Engineering, Chongqing University, Chongqing, 400044, China

    Zuofa Liu, Jie Zhou, Zhiyuan Qu & Xi Wang

  2. College of Mechanical Engineering, Chongqing Technology and Business University, Chongqing, 400060, China

    Qiang Liang

  3. College of Mechanical Engineering, Chongqing University of Technology, Chongqing, 400054, China

    Wenjie Feng

Authors
  1. Zuofa Liu
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  2. Jie Zhou
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  3. Zhiyuan Qu
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  4. Xi Wang
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  5. Qiang Liang
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  6. Wenjie Feng
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Contributions

Zuofa Liu and Wenjie Feng conceived and designed the study. Zuofa Liu, Zhiyuan Qu, Xi Wang, and Jie Zhou performed the experiments. Jie Zhou provided funding. Zuofa Liu and Jie Zhou wrote the paper. Wenjie Feng, Qiang Liang, Zhiyuan Qu, and Xi Wang reviewed and edited the manuscript. All authors read and approved the manuscript.

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Correspondence to Jie Zhou or Wenjie Feng.

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Liu, Z., Zhou, J., Qu, Z. et al. A precision sizing method for cold extruded sun gear with internal-external tooth shapes. Int J Adv Manuf Technol 115, 3331–3344 (2021). https://doi.org/10.1007/s00170-021-07405-8

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  • DOI: https://doi.org/10.1007/s00170-021-07405-8

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