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A Rotary Compression Process for Producing Hollow Gear Shafts.
Arkadiusz Tofil1, Janusz Tomczak1, Tomasz Bulzak1
1Faculty of Mechanical Engineering, Lublin University of Technology, 36 Nadbystrzycka Str, 20-618 Lublin, Poland.
Materials (Basel, Switzerland)
|December 18, 2020
Summary
Rotary compression can form hollow stepped gear shafts, but it's best done in two operations. This method involves initial shaft formation followed by gear creation on the shaft.
Area of Science:
- Materials Science and Engineering
- Manufacturing Processes
- Mechanical Engineering
Background:
- Hollow stepped gear shafts are critical components in various mechanical systems.
- Traditional manufacturing methods may have limitations in efficiency and precision.
- Rotary compression offers a potential alternative for producing these complex parts.
Purpose of the Study:
- To evaluate the effectiveness of rotary compression for producing hollow stepped gear shafts.
- To identify the limitations and optimal process parameters for this manufacturing technique.
- To determine if a single-operation process is feasible.
Main Methods:
- Numerical modeling using the finite element method (FEM) with Simufact Forming software.
- 3D simulations to analyze material flow, thermal, and force parameters.
- Experimental verification using a specialized rotary compression machine for hollow parts.
Main Results:
- The study found that forming a complete stepped gear shaft in a single rotary compression operation is challenging.
- Material flow and process parameters were analyzed through simulations and experiments.
- Experimental results validated the findings from the finite element method analysis.
Conclusions:
- Hollow stepped gear shafts are best manufactured in two distinct operations using rotary compression.
- The first operation focuses on forming the hollow stepped shaft.
- The second operation involves creating the gear feature on one of the shaft's steps.
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