A Study on Two-Stage Cold Forging for a Drive Shaft with Internal Spline and Spur Gear Geometries
Abstract
:1. Introduction
2. Materials and Methods
2.1. Description of Drive Shaft
2.2. Process Design for Two-Stage Cold Forging
3. Mechanical Properties and Finite Element Models
3.1. Mechanical Properties of AISI 1035 Carbon Steel
3.2. Three-Dimensional Finite Element Models
4. Numerical Simulations
4.1. Forward Extrusion Simulation for Preform
4.2. Forward-Backward Extrusion Simulation for Drive Shaft
4.3. Forging Load Predictions
5. Cold Forging Experiments for the Preform and Drive Shaft
6. Results and Discussions
6.1. 3D Shape Measurement of the Cold Forged Preform and Drive Shaft
6.2. Dimensional Suitability of the Preform
6.3. Geometric Accuracy of the Drive Shaft
7. Conclusions
- (1)
- To improve the workability and mechanical properties of AISI 1035 medium carbon steel material as cold-drawn round bar, spheroidizing and annealing were conducted. As a result of the spheroidizing annealing, the average grain size, which was initially measured to be about 8.84 μm for the raw material, was slightly increased to approximately 9.36 μm. This ensured that the heat treated AISI 1035 workpiece was well spheroidized. In addition, a series of uni-axial tensile and compressive tests were performed to investigate the mechanical properties before and after the spheroidizing and annealing, and the evaluated mechanical properties were confirmed to be enough improved for applying the two-stage cold forging process.
- (2)
- FEM-based cold forging simulations were performed to verify the suitability of the proposed two-stage cold forging, and the forging loads were also predicted. First, the forward extrusion process was numerically simulated to realize the preform from the spheroidizing annealed AISI 1035 round billet, thereafter, the forward-backward extrusion was also analyzed to visualize the drive shaft from the preform. As a result, it was ensured that the preform and the drive shaft could be successfully extruded without critical defects.
- (3)
- The cross-sectional configurations of the preform and the drive shaft derived from the numerical cold extrusion simulations and the 3D scanned features were compared with the required target geometries. The excessive deformations and the considerable dimensional errors were then locally observed around the tooth ends on the forward extruded spur gear region and the protruded extremity at the central area of the lower shaft, but these errors were ignored after consideration of the required dimension and its permissible error. Consequently, it was verified that the dimensional variations of the preform and the drive shaft satisfied each other well.
- (4)
- Finally, it was ensured that the two-stage cold forging process, which was composed of the preform operation and the forward-backward extrusion, can be successfully applied for producing the drive shaft with an irregular hexadecagonal deep groove and sixteen-tooth spur gear geometries.
Funding
Conflicts of Interest
References
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Element | C | Mn | Si | P | S | Fe |
---|---|---|---|---|---|---|
wt% | 0.350 | 0.800 | 0.275 | 0.003 | 0.005 | Bal. |
Tensile Properties | Raw Material | Annealed Material |
---|---|---|
Young’s Modulus (GPa) | 196 | 196 |
Yield Strength (MPa) | 410 | 350 |
Ultimate Strength (MPa) | 755 | 643 |
Poisson’s Ratio | 0.29 | 0.29 |
Fracture Strain | 0.28214 | 0.32096 |
Geometric Feature | Required Dimension | Permissible Reference | Dimensional Value | |||
---|---|---|---|---|---|---|
Predicted | Measured | |||||
Preform | Upper Head | Outer Diameter | Φ51.0 | ±0.25 | 0.00 | 0.02 |
Length | 96.0 | ±1.00 | 0.28 | −0.65 | ||
Lower Shaft | Outer Diameter | Φ36.7 | ±0.25 | −0.02 | −0.03 | |
Length | 33.5 | ±1.50 | 0.07 | 1.04 | ||
Drive Shaft | Upper Head | Outer Diameter | Φ51.6 | ±0.25 | 0.01 | −0.04 |
Length | 36.5 | ±1.50 | −0.01 | −0.25 | ||
Groove Depth | 22.7 | −0.20~1.50 | 1.28 | −0.13 | ||
Spur Gear | Face Width | 92.0 | ±1.50 | −0.65 | −0.49 | |
Tooth Height | 5.9 | ±0.25 | 0.00 | 0.12 | ||
Root Diameter | Φ37.1 | ±0.25 | 0.00 | 0.00 | ||
Lower Shaft | Outer Diameter | Φ36.7 | ±0.25 | −0.01 | 0.24 | |
Length | 35.0 | ±1.50 | −2.05 | −1.05 |
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Ku, T.-W. A Study on Two-Stage Cold Forging for a Drive Shaft with Internal Spline and Spur Gear Geometries. Metals 2018, 8, 953. https://doi.org/10.3390/met8110953
Ku T-W. A Study on Two-Stage Cold Forging for a Drive Shaft with Internal Spline and Spur Gear Geometries. Metals. 2018; 8(11):953. https://doi.org/10.3390/met8110953
Chicago/Turabian StyleKu, Tae-Wan. 2018. "A Study on Two-Stage Cold Forging for a Drive Shaft with Internal Spline and Spur Gear Geometries" Metals 8, no. 11: 953. https://doi.org/10.3390/met8110953