engleski

Experimentally aided creation of numerical model of radial gear extrusion in cold state

The objective of this article is numerical and experimental research of the net shape forming in the process of radial gear extrusion in cold state. Experiment was carried out using Al99.5 as a modeling material to record the force-stroke diagram. In the end of forming process, gear geometry was cut in horizontal and vertical planes to measure the hardness with the aim to compare the results and numerical simulation. Numerical simulation was carried out in MSC.Marc Mentat 2003, a commercial program package capable of dealing with finite strain using the Finite Elements Method. Offering a great number of modeling possibilities, numerical simulation was considered as a technology. Therefore the experimental model was needed to asset the optimal FE model, capable of capturing the physical phenomena like finite strain, strain hardening and friction. Comparison between the FE simulation and the experiment was done via numerically and experimentally obtained force-stroke diagram and via comparison of the measured hardness with numerically obtained equivalent strain. Comparative analysis of the results has shown that the actual mesh geometry, friction model and updated Lagrangian formulation of the finite strain, represent a satisfying numerical model of a gear extrusion in cold state. Refined by the experiment, obtained FE model can be applied to the other gear geometries only by making minor, geometrical changes in numerical model.

radial gear extrusion; numerical simulation; finite elements method

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