Investigation of externally toothed parts forming using ballizing technique
Externally toothed parts such as gears, splined and coupling sleeves can be manufactured by machining, casting, and forming. The machining process is costly because of using a special tool, consuming power, and wasting material during the machining process. The casting processes usually need other f...
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Elsevier
2024-12-01
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| Series: | Results in Materials |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2590048X24001146 |
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| author | Ayman Ali Abd-Eltwab Essam Khalaf Saied Ahmed Mohamed Atia Nouby M. Ghazaly A.A. Gomaa Karim Mohamed Atia |
| author_facet | Ayman Ali Abd-Eltwab Essam Khalaf Saied Ahmed Mohamed Atia Nouby M. Ghazaly A.A. Gomaa Karim Mohamed Atia |
| author_sort | Ayman Ali Abd-Eltwab |
| collection | DOAJ |
| description | Externally toothed parts such as gears, splined and coupling sleeves can be manufactured by machining, casting, and forming. The machining process is costly because of using a special tool, consuming power, and wasting material during the machining process. The casting processes usually need other finishing processes. In this study, a new forming tool based on the ballizing technique is suggested to perform the forming of the toothed parts with external splines in one stroke. The set is made up of six steel balls each having a 20 mm diameter. The process was performed on the lathe machine with data acquisition recording to record the process consumed load. Die with splines on the inner surface opposite the required splines was mounted in the lath check. The required tooth shape was obtained by forcing the forming tool into the hole by pushing the specimen into the die cavity. the mathematical model was formulated to calculate required force deformation. The model depends on the process dynamics and contact area between the tool and the specimen. The effect of process parameters on the load and the product properties was conducted. The study parameters were forming depths of 2, 3, 4, and 5 mm, the rotational speed of 50, 76, 120, and 150 rpm, axial feed 0.1, 0.15, 0.3, and 0.6 mm/rpm specimen inner diameter of 66, 64, 62 and 60 mm. A comparison was made between results of mathematical model and results of experimental. Rotational speed, axial feed, and cross-in feed were found to be the three factors that have the greatest impact on forming load and overall product quality. Also, it was found that deformation load increased with the increasing rotational speed, cross-in feed, and axial feed. |
| format | Article |
| id | doaj-art-53ec917062fd4baf966c8534a7c79429 |
| institution | Kabale University |
| issn | 2590-048X |
| language | English |
| publishDate | 2024-12-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Results in Materials |
| spelling | doaj-art-53ec917062fd4baf966c8534a7c794292024-12-15T06:16:32ZengElsevierResults in Materials2590-048X2024-12-0124100640Investigation of externally toothed parts forming using ballizing techniqueAyman Ali Abd-Eltwab0Essam Khalaf Saied1Ahmed Mohamed Atia2Nouby M. Ghazaly3A.A. Gomaa4Karim Mohamed Atia5Mechanical Engineering Department, Faculty of Engineering, Beni-Suef University, Beni-Suef, 62511, Egypt; Corresponding author.Mechanical Engineering Department, Faculty of Engineering, Beni-Suef University, Beni-Suef, 62511, EgyptMechanical Engineering Department, Faculty of Engineering, Assiut University, Assiut, EgyptTechnical College, Imam Ja'afar Al-Sadiq University, Baghdad, Iraq; Mechanical Engineering Department, Faculty of Engineering, South Valley University, Qena, 83523, EgyptMechanical Engineering Department, Faculty of Engineering, South Valley University, Qena, 83523, EgyptProduction and Design Engineering Department, Minia University, El Minia, EgyptExternally toothed parts such as gears, splined and coupling sleeves can be manufactured by machining, casting, and forming. The machining process is costly because of using a special tool, consuming power, and wasting material during the machining process. The casting processes usually need other finishing processes. In this study, a new forming tool based on the ballizing technique is suggested to perform the forming of the toothed parts with external splines in one stroke. The set is made up of six steel balls each having a 20 mm diameter. The process was performed on the lathe machine with data acquisition recording to record the process consumed load. Die with splines on the inner surface opposite the required splines was mounted in the lath check. The required tooth shape was obtained by forcing the forming tool into the hole by pushing the specimen into the die cavity. the mathematical model was formulated to calculate required force deformation. The model depends on the process dynamics and contact area between the tool and the specimen. The effect of process parameters on the load and the product properties was conducted. The study parameters were forming depths of 2, 3, 4, and 5 mm, the rotational speed of 50, 76, 120, and 150 rpm, axial feed 0.1, 0.15, 0.3, and 0.6 mm/rpm specimen inner diameter of 66, 64, 62 and 60 mm. A comparison was made between results of mathematical model and results of experimental. Rotational speed, axial feed, and cross-in feed were found to be the three factors that have the greatest impact on forming load and overall product quality. Also, it was found that deformation load increased with the increasing rotational speed, cross-in feed, and axial feed.http://www.sciencedirect.com/science/article/pii/S2590048X24001146Externally toothed partsGearsCoupling sleevesBallizing processSpinningMathematical model |
| spellingShingle | Ayman Ali Abd-Eltwab Essam Khalaf Saied Ahmed Mohamed Atia Nouby M. Ghazaly A.A. Gomaa Karim Mohamed Atia Investigation of externally toothed parts forming using ballizing technique Results in Materials Externally toothed parts Gears Coupling sleeves Ballizing process Spinning Mathematical model |
| title | Investigation of externally toothed parts forming using ballizing technique |
| title_full | Investigation of externally toothed parts forming using ballizing technique |
| title_fullStr | Investigation of externally toothed parts forming using ballizing technique |
| title_full_unstemmed | Investigation of externally toothed parts forming using ballizing technique |
| title_short | Investigation of externally toothed parts forming using ballizing technique |
| title_sort | investigation of externally toothed parts forming using ballizing technique |
| topic | Externally toothed parts Gears Coupling sleeves Ballizing process Spinning Mathematical model |
| url | http://www.sciencedirect.com/science/article/pii/S2590048X24001146 |
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