Tofil Arkadiusz, Tomczak Janusz, Bulzak Tomasz, Pater Zbigniew, Buczaj Marcin, Sumorek Andrzej
Faculty of Mechanical Engineering, Lublin University of Technology, 36 Nadbystrzycka Str, 20-618 Lublin, Poland.
Faculty of Electrical Engineering and Computer Science, Lublin University of Technology, 38A Nadbystrzycka Str, 20-618 Lublin, Poland.
Materials (Basel). 2020 Dec 15;13(24):5718. doi: 10.3390/ma13245718.
This paper presents selected numerical and experimental results of a study investigating the process of forming hollow stepped gear shafts from tubes by rotary compression. The objective of the study was to determine whether the rotary compression process is an effective method of producing hollow stepped gear shafts and to identify limitations of this manufacturing method. A theoretical analysis involved the numerical modeling of the proposed process by the finite element method (FEM). 3D simulations were performed using the commercial simulation software package Simufact Forming. The analysis involved examining the material flow pattern along with thermal and force parameters of the process. The FEM results were verified with experimental tests conducted under laboratory conditions. The experiments were performed on a machine specially designed for the rotary compression of hollow parts. Results demonstrate that it is difficult to form a stepped gear shaft in one operation. For this reason, such parts should be formed in two operations. The first operation involves the forming of a hollow stepped shaft by rotary compression, while in the second operation, a gear is formed on one of the steps of the shaft.
本文介绍了一项研究的部分数值和实验结果，该研究旨在探究通过旋转压缩由管材制造空心阶梯齿轮轴的过程。该研究的目的是确定旋转压缩工艺是否是生产空心阶梯齿轮轴的有效方法，并识别这种制造方法的局限性。理论分析包括通过有限元方法（FEM）对所提出的工艺进行数值建模。使用商业模拟软件包Simufact Forming进行了三维模拟。分析涉及研究材料流动模式以及该工艺的热参数和力参数。有限元方法的结果通过在实验室条件下进行的实验测试进行了验证。实验在专门设计用于空心零件旋转压缩的机器上进行。结果表明，在一次操作中很难形成阶梯齿轮轴。因此，此类零件应分两次操作成型。第一次操作是通过旋转压缩形成空心阶梯轴，而在第二次操作中，在轴的一个台阶上形成齿轮。
