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International Journal of Forming Processes
1292-7775
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 ARTICLE VOL 9/3 - 2006  - pp.259-286  - doi:10.3166/ijfp.9.259-286
TITLE
Helical Gear Forging Simulation using Recurrent Boundary Conditions

ABSTRACT
In gear forging simulation, the use of symmetries is obviously an efficient solution to reduce the computational time. However, for helical gears, standard plane symmetry conditions do not hold. They have to be extended to recurrent boundary conditions where the material flow that leaves one of the symmetry surface re-enters through the symmetric one, which is derived from it by a rotation of 2/Nteeth radians, (Nteeth is the number of teeth of the gear). In this case, the symmetry surfaces are not necessarily plane. This paper presents a master-slave algorithm for imposing these conditions, both for velocities and temperatures. It makes it possible to carry out simulations of helical gear forging considering only one tooth. Using a Lagrangian mesh, the symmetry surfaces are not steady during the deformation process, so a special treatment is required to handle the contact with deformable tools in the recurrent frame. Academic tests are studied to evaluate the accuracy of this approach, and then industrial applications show its robustness.


AUTEUR(S)
Sorin POPA, Lionel FOURMENT

KEYWORDS
Recurrent Boundary Conditions, Master-Slave Algorithm, Forging, Helical Gear, Contact Between Deformable Bodies.

LANGUE DE L'ARTICLE
Anglais

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