TY - JOUR

T1 - Cold Sizing of Cold- and Hot-Formed Gears

AU - Behrens, B. A.

AU - Doege, E.

PY - 2004

Y1 - 2004

N2 - Today's markets require industrial forgers to manufacture complex near net shape or net shape parts at minimum unit costs. One way of meeting this challenge is to combine a cold or hot forming process with a subsequent cold sizing process in order to achieve the desired tolerances. In this context, a closed-die cold sizing process of a straight-toothed planetary gear has been investigated in terms of the occurring elastic die deflection which is a threat to accuracy in this and any other cold forming process. Two strategies have been employed to minimize the elastic die deflection. The first strategy consists in a correction of the die cavity's tooth profile based on the finished part's deviation from its theoretical shape determined through Finite-Element-Analysis (FEA). The key idea underlying the second strategy is an innovative tooling concept which compensates the elastic die deflection by means of a counter pressure generated by an elastomer ring embedded in the lower die. The advantages of this active concept have been confirmed in numerical and experimental investigations.

AB - Today's markets require industrial forgers to manufacture complex near net shape or net shape parts at minimum unit costs. One way of meeting this challenge is to combine a cold or hot forming process with a subsequent cold sizing process in order to achieve the desired tolerances. In this context, a closed-die cold sizing process of a straight-toothed planetary gear has been investigated in terms of the occurring elastic die deflection which is a threat to accuracy in this and any other cold forming process. Two strategies have been employed to minimize the elastic die deflection. The first strategy consists in a correction of the die cavity's tooth profile based on the finished part's deviation from its theoretical shape determined through Finite-Element-Analysis (FEA). The key idea underlying the second strategy is an innovative tooling concept which compensates the elastic die deflection by means of a counter pressure generated by an elastomer ring embedded in the lower die. The advantages of this active concept have been confirmed in numerical and experimental investigations.

KW - Cold sizing process

KW - Forming

KW - Gear

UR - http://www.scopus.com/inward/record.url?scp=3142665503&partnerID=8YFLogxK

U2 - 10.1016/S0007-8506(07)60688-X

DO - 10.1016/S0007-8506(07)60688-X

M3 - Article

AN - SCOPUS:3142665503

VL - 53

SP - 239

EP - 242

JO - CIRP Annals - Manufacturing Technology

JF - CIRP Annals - Manufacturing Technology

SN - 0007-8506

IS - 1

ER -