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Numerical investigation on tooth filling of clutch drum forming processes

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Abstract

The formation of the gear drum clutch involves bulk and sheet forming, and filling the tooth is a key difficulty during the forming process. In this study, four tooth extrusion processes with various extrusion ratios and preform shape were developed, and they were simulated using AFDEX software for examining how the clutch drum influenced tooth forming. Various tooth-filling results were obtained by controlling the extrusion ratio and die cavity in each process. A comparison of the deformation, material flow, and mean stress state among the processes revealed that the stress state was the main determinant of the local flowing material, and it was used to improve the degree of tooth filling. The optimal tooth-filling result was obtained using a two-step extrusion process with an appropriate extrusion ratio and a preform shape.

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Acknowledgments

This work was supported by the National Natural Science Foundation of China (Grant No. 51475296) and the State Key Laboratory of Materials Processing and Die & Mould Technology, Huazhong University of Science and Technology, China (Grant No. P201513). The useful discussion with Prof. Mathias Liewald from IFU, University of Stuttgart on the plate with larger radius might have better degree of tooth filling during the 48th ICFG Plenary Meeting in Daejeon, Korea should be mentioned.

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Authors and Affiliations

  1. Institute of Forming Technology and Equipment, National Engineering Research Center of Die and Mold, Shanghai Jiao Tong University, 1954 Huashan Road, Shanghai, 200030, People’s Republic of China

    Xiaolong Sun, Shengfa Zhu, Xincun Zhuang & Zhen Zhao

  2. State Key Laboratory of Mould and Die Technology, Huazhong University of Science and Technology, Wuhan, 430074, People’s Republic of China

    Xincun Zhuang

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  1. Xiaolong Sun
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  2. Shengfa Zhu
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  4. Zhen Zhao
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Correspondence to Zhen Zhao.

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Sun, X., Zhu, S., Zhuang, X. et al. Numerical investigation on tooth filling of clutch drum forming processes. Prod. Eng. Res. Devel. 10, 25–35 (2016). https://doi.org/10.1007/s11740-016-0658-7

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