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2 2020

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Thermomechanical Analysis of the Possibility of Using New Methods of Complex Extrusion for Manufacturing the Inner Toothing of Spline Sleeves

Michalczyk J., Wiewiórowska S.

Archives of Metallurgy and Materials

2020

Vol. 65, iss. 4

1447--1453

In the paper presents two new patented of unconventional methods author’s and sleeve-type products of extruding [PL219182, PL221425]. The extrusion methods have been developed with the aim of reducing the energy and force parameters during the plastic forming of material. Traditional methods of extruding similar products are characterized by considerably higher extrusion force magnitudes. This results in substantial limitations and problems of an engineering nature. Moreover, the proposed methods of producing bottomed and bottomless sleeves are distinguished by the capability to minimize or totally eliminate the waste. The author’s methods of extruding long bottomless sleeves, presented herein, were used for developing a method for shaping inner toothing in spline sleeves. The theoretical analysis is based on thermomechanical simulation of the possibility of applying such processes to the extrusion of spline shafts with inner toothing. Next, the obtained results were compared with analogous parameters for classical indirect extrusion. The possibility of shaping inner toothing over the entire product length according to the proposed spline sleeve plastic forming methods was also explored.

New Unconventional Processes of Plastic Forming of the Internal Toothing of Coupling Spline Sleeves

Michalczyk J., Wiewiórowska S.

Archives of Metallurgy and Materials

2020

Vol. 65, iss. 1

229--236

The article explores the possibility of using the authors’ three new methods of unconventional extrusion of deep hollows to be used for the manufacture of spline sleeves intended for internal toothing couplings. Two invention patents, PL206466 and PL224121, and one patent application, P.416772, were used for this purpose. Numerical computations were made in the Forge®3D program for the conceptual schemes of forming sleeves. The aim of those computations was to determine the extrusion forces and to compare them with the conventional indirect and direct extrusion methods. Then, on models based on the authors’ plastic forming schemes, numerical computations were made, from which the actual energy and force parameters were determined in the form of the relationship of extrusion force versus forming tool path. Also, the degree of fill of the passes, in which spline sleeve toothing is formed, was determined.