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العنوان
Toothed Parts Forming Using Rotary Forging Technique /
المؤلف
Fahmy, Emad Abdel Fattah Ali.
هيئة الاعداد
باحث / عماد عبد الفتاح علي فهمي السيد
مشرف / محمد نجيب الشيخ
مشرف / رجب كمال فهيم
مشرف / أحمد السيد محمد حسن
الموضوع
Steel.
تاريخ النشر
2020.
عدد الصفحات
105 p. :
اللغة
الإنجليزية
الدرجة
ماجستير
التخصص
الهندسة الصناعية والتصنيع
الناشر
تاريخ الإجازة
15/3/2020
مكان الإجازة
جامعة بني سويف - كلية التعليم الصناعي - الميكانيكا (إنتاج)
الفهرس
Only 14 pages are availabe for public view

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Abstract

The toothed parts forming process, or gears, main task is to apply a definite tool to press vertically against the bulk section area. Cold rotary forging is understood to be an advanced and much complex incremental metal forming process. That is because of many factors such as, coupling interactive effects and its availability to form various asymmetrical parts from cylindrical bars. Performance of toothed parts forming process is by using machines such as hobbing or milling or casting or others, which cost much effort, time, money and energy. Another advantage of this process is that it is created with only one simple tool and produced in a single operation by complex forging lath using rotating tool. As it has the ability to form it easily. Furthermore, formed gears have many applications in the mechanical fields.
In the present work, a new technique of toothed parts forming technique using cold rotary forging process was studied. A new tool was designed according to the filling ratio (FR) to form the toothed parts. FR is defined as the ratio of volume of the formed gear external teeth (V_t) to volume of die cavity (splines) (V_d).
Several formed gears specimens of lead were conducted at different working conditions. These working conditions were inclination angle (5˚, 8 ̊, 11̊, and14˚), axial feed (0.13, 0.16, and 0.18) mm/rev, and rotating speed (50, 80, and 125) rpm. Thirty-six (3x3x4=36) specimens were carried out, i.e. three different rotational speeds, three axial feeds, and four inclination angles were varied to each other in each experiment. The effect of these working conditions on the forming loads (axial, radial, and tangential) were investigated. The forming loads were measured by a data logger that connected to a dynamometer to read and record the forming loads. Also, a parametric study was carried out to illustrate the effect of the working conditions on the characteristics of the formed part.
The results showed that these working conditions have a clear influence on the forming forces along formed part to determine filling ratio occurrence. Also, showed the surface quality occurred during the forming process due to the contact in force between the forming tool and specimens.
The results concluded that the axial load had the greatest effect, while radial and tangential loads had a slight effect. Also, the maximum forming load had an explicit effect with increasing the axial feeds, while the resultant loads increased with increasing of the filling ratio. Conversely, the resultant loads decreased with decreasing of rotational speeds. Along the formed portion, the height of the teeth filling started at the free end then increased gradually as a result of flowing the metal (the tool penetration in the metal) until filling up cavity of the die (splines). Then, the metal flowing increased gradually towards the chuck side until the filling ratio has reached to approximately 100%. After that, out excess of the die metal occurred back extrusion as a result of increasing in diminutions of the tool, and got decreased in the fill rate if diminutions of the tool was small. On other hand, the forming loads decreased gradually with increasing inclination angle (degree), while it increased with increasing of rotational speed and axial feed.