Material saving by a combination of rotary forging and conventional processes: Hybrid forging for net-shape gear: Hybrid forging for net-shape gear

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dc.contributor.authorVarela, Sonia
dc.contributor.authorValbuena, Oscar
dc.contributor.authorArmentia, Jorge
dc.contributor.authorLarrucea, Francisco
dc.contributor.authorManso, Virginia
dc.contributor.authorSantos, Maite
dc.contributor.editorArrazola, Pedro
dc.contributor.editorSaenz de Argandona, Eneko
dc.contributor.editorOtegi, Nagore
dc.contributor.editorMendiguren, Joseba
dc.contributor.editorSaez de Buruaga, Mikel
dc.contributor.editorMadariaga, Aitor
dc.contributor.editorGaldos, Lander
dc.contributor.institutionPROMETAL
dc.contributor.institutionINDUSTRY_THINGS
dc.contributor.institutionSG
dc.date.issued2019-07-02
dc.descriptionPublisher Copyright: © 2019 Author(s).
dc.description.abstractIncreasing efficiency in raw material and energy usage is vital, even more in sectors, such as the hot forging industry, where material accounts for 50% of component price and energy costs are continuously rising. One of the methods to achieve this is to minimize material waste. Traditionally, high-quality gears for the automotive sector are machined to shape from forged preforms which is wasteful of both materials and energy. Attention has now turned to the forging of tooth gears by conventional forging. However, this could require high forging loads and therefore huge press sizes. Some gears may also be difficult to form due to the placement of their teeth. Forging of tooth gears is thus not a straightforward task. In this context, rotary forging is a powerful alternative. It uses incremental deformation locally with the material to achieve near net shape results, minimizing machining. Due to the reduction in contact, it also allows the forging load to be decreased substantially, resulting in smaller presses. This paper shows the development of the rotary forging process in combination with conventional forging to obtain crown gear teeth as a demonstration case. First, the hot conventional forging is shown, based on obtaining the rotary preform by a closed die forging operation. Then rotary forging is defined as a semi-finished operation to achieve the forged teeth. The objective is to reduce the initial billet weight, checking that folds and filling defects do not appear. A thermomechanical chained model has been developed based on FEM and experimental tests carried out in a pre-industrial environment. The prototypes result in increased yield from raw material (around 15% saving compared to machining) and they can be manufactured with less than 50% of the load required by conventional forging processes. Quality and metallographic requirements are also fulfilled.en
dc.description.statusPeer reviewed
dc.format.extent1
dc.format.extent1181448
dc.identifier.citationVarela , S , Valbuena , O , Armentia , J , Larrucea , F , Manso , V & Santos , M 2019 , Material saving by a combination of rotary forging and conventional processes: Hybrid forging for net-shape gear : Hybrid forging for net-shape gear . in P Arrazola , E Saenz de Argandona , N Otegi , J Mendiguren , M Saez de Buruaga , A Madariaga & L Galdos (eds) , unknown . vol. 2113 , 0094-243X , American Institute of Physics Inc. , pp. 40015 , 22nd International ESAFORM Conference on Material Forming, ESAFORM 2019 , Vitoria-Gasteiz , Spain , 8/05/19 . https://doi.org/10.1063/1.5112549
dc.identifier.citationconference
dc.identifier.doi10.1063/1.5112549
dc.identifier.isbn9780735418479
dc.identifier.otherresearchoutputwizard: 11556/835
dc.identifier.urlhttp://www.scopus.com/inward/record.url?scp=85068878974&partnerID=8YFLogxK
dc.language.isoeng
dc.publisherAmerican Institute of Physics Inc.
dc.relation.ispartofunknown
dc.relation.ispartofseries0094-243X
dc.rightsinfo:eu-repo/semantics/restrictedAccess
dc.subject.keywordsRaw material
dc.subject.keywordsEnergy
dc.subject.keywordsEfficiency
dc.subject.keywordsRaw material
dc.subject.keywordsEnergy
dc.subject.keywordsEfficiency
dc.subject.keywordsGeneral Physics and Astronomy
dc.subject.keywordsSDG 9 - Industry, Innovation, and Infrastructure
dc.subject.keywordsFunding Info
dc.subject.keywordsThis work was supported by the Basque Government under the CORONAT project (Hazitek program: IG2015/00331, ZL-2016/00070, ZL-2017/00109). The authors wish to thank FORGE ® NxT for their assistance on simulation methodology and INDUSTRIAS PUIGJANER S.A for use of the forging tool system developed.
dc.subject.keywordsThis work was supported by the Basque Government under the CORONAT project (Hazitek program: IG2015/00331, ZL-2016/00070, ZL-2017/00109). The authors wish to thank FORGE ® NxT for their assistance on simulation methodology and INDUSTRIAS PUIGJANER S.A for use of the forging tool system developed.
dc.titleMaterial saving by a combination of rotary forging and conventional processes: Hybrid forging for net-shape gear: Hybrid forging for net-shape gearen
dc.typeconference output
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