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Investigation of Hardness, Microstructure, and Process Temperature in the Internal Gear Flow-Forming Process

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Abstract

The advantages of the flow-forming process, such as excellent mechanical properties, simple tools, and the need for low forming force, have led to the increasing use of this process in various industries, especially in the military, aerospace, and automotive industries. New application of this process is the internal gear flow-forming process (IGFP), in which the gear is produced with simple tools and low forming force. In this paper, IGFP was studied by the finite element method and experiments. Experiments include tensile test (determine stress-strain curve of the material), ring compression test (determine friction coefficient), flow-forming test, and metallography. The material was considered elastic-plastic, and the Coulomb friction model was used to simulate the friction between surfaces. IGFP was performed by a simple setup. Teeth height and gear profile were measured and compared to simulated values, and there is a good agreement between the simulation and experimental results. Once the simulation is verified, the effects of process parameters (feed rate, roller diameter, attack angle of the roller, and thickness reduction percentage) on the process temperature were obtained using the design of experiments (DOE). According to DOE results, thickness reduction percentage (T) and roller diameter (D) have the most significant effect on process temperature. Finally, a function for process temperature was obtained versus input parameters, and this function was optimized by the firefly algorithm.

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Authors and Affiliations

  1. Department of Mechanical Engineering, University of Birjand, Birjand, Iran

    M. Khodadadi, K. Khalili & A. Ashrafi

  2. Department of Mechanical Engineering, Ferdowsi University of Mashhad, Mashhad, Iran

    F. Kolahan

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  1. M. Khodadadi
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  2. K. Khalili
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  3. A. Ashrafi
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  4. F. Kolahan
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Corresponding author

Correspondence to K. Khalili.

Ethics declarations

1. ​The study does not involve the sampling/participation of humans or animals in any aspect.

2. All authors made substantial contributions and contributed equally to the manuscript in all aspects.

3. The study was not funded by any funding organization.

4. The authors declare that there is no conflict of interest.

5. The datasets generated, and/or analyzed during the current study are available from the corresponding author on reasonable request.

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Khodadadi, M., Khalili, K., Ashrafi, A. et al. Investigation of Hardness, Microstructure, and Process Temperature in the Internal Gear Flow-Forming Process. Exp Tech 47, 1169–1182 (2023). https://doi.org/10.1007/s40799-022-00622-0

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