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A Study on the Extrusion by a two-step process for manufacturing helical gear

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Abstract

Much research has been carried out in the manufacturing of helical gears by cold forging or by extrusion. Although cold forging is applied to some bevel, spur, and helical gears, problems in connection with the reduction forming load and tool life still make it difficult for these methods to be commercialized. In this study, focusing on reducing a load in forming helical gears, the extrusion of helical gears by two-step process is proposed. This process is composed primarily of extruding a billet to a spur gear and then twisting the previous spur gear extruded to a helical gear. Cylindrical billets of Cr-Mo steel(SCM 415) and aluminium alloy(Al60 series) were used as specimen materials for the experiments. The maximum loads obtained by upper-bound analysis and FEM are compared with the results of experiments. The loads of the analysis have good agreements with those of the experiment. The newly proposed method can be used as an advanced technique that remarkably reduces the forming load and replaces the conventional forming.

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Authors and Affiliations

  1. Research Institute of mechanical technology, Pusan National University, JangJeon-Dong, Keumjung-Ku, Busan, 609–735, Korea

    Sung-Yuen Jung & Chul Kim

  2. NCRC for Hybrid Materials Solution, Pusan National University, San30, JangJeon-Dong, Keumjung-Ku, Busan, 609–735, Korea

    Myung-Chang Kang

  3. Division of Mech. Indus. Sys. Eng., Dong Eui University, Busan, 614–714, Korea

    Chang-Ho Kim

  4. School of Mechanical Engineering, Pusan National University, Busan, 609–735, Korea

    Young-June Chang

  5. Department of Biomedical Engineering, Kyung Hee University, Seoul, 130–731, Korea

    Seungr-Moo Han

Authors
  1. Sung-Yuen Jung
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  2. Myung-Chang Kang
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  3. Chul Kim
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  4. Chang-Ho Kim
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  5. Young-June Chang
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  6. Seungr-Moo Han
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Corresponding author

Correspondence to Chul Kim.

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Jung, SY., Kang, MC., Kim, C. et al. A Study on the Extrusion by a two-step process for manufacturing helical gear. Int J Adv Manuf Technol 41, 684–693 (2009). https://doi.org/10.1007/s00170-008-1518-1

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  • DOI: https://doi.org/10.1007/s00170-008-1518-1

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