The Preform and Cold Forging Die Design for a Hollow Bushing Part with Face Gear Features

具端面齒型特徵之中空襯套預成形及冷鍛模具設計

許進忠(Jinn-Jong Sheu) ； 余征諴(Cheng-Hsien Yu) ； 蔡全順(Chiuan-Shuen Tasi)

《中國機械工程學刊》 36卷1期 (2015/02) Pp. 75-84

摘要

本文提出預成形及冷鍛模具設計並使用三動式沖床製造二端面有小齒型特徵之中空襯套，因具有高細長比、非均勻厚度中空件及二端面有小齒型特徵導致充模困難及高成形負荷。本文提出第一種方案，使用三動式沖床以一道次方法做出留有腹板及所有幾何特徵之中空件，以評估成形困難點及可能缺陷。本文另提出第二種方案，使用三動式沖床設計二道次預成形，再以三動式精鍛做出二端面齒形。以一溢料環設計改善充模之材料流動並降低成形負荷，所有設計經FEM評估，最後以實驗方法驗證所提出設計方法，實驗結果與分析吻合，驗證本文方法之可行性。

並列摘要

In this study, process and cold forging die designs were proposed to make a hollow part with small gear shapes on both ends with a triple-action press. The characteristics of high slenderness ratio, non-uniform hollow part thickness, and small gear shapes on both-ends result in difficulty of die filling and high forging load. First approach, one-pass forging die design was adopted to make all features of the part with an inner web and evaluate the forming difficulty and defects of triple-action forging process. Second approach, a multi-pass process design of two preforms was proposed to make hollow part without small gear shape on open ends. A finish triple-action forging design was proposed to produce the small features on open ends. A flash ring around the small features of the part was designed to improve the material flow of die filling and decrease the forming load. The parameters of preform and finish forging die designs were studied using the FEM simulation processes. The forging experiments were carried out to verify the proposed method, the experiment results showed good agreement with the simulations.

並列關鍵字

Multi-pass forging process ； Preform design ； Suspension bushing ； CAE