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FE-based Design of a Forging Tool System for a Hybrid Bevel Gear

Autoren:Behrens, B.-A.; Bouguecha, A.; Bonk, C.; Bonhage, M.; Chugreeva, A.; Matthias, T.
Kategorie:Zeitschriften/Aufsätze (reviewed)
Jahr:2017
Veröffentlichung:Key Engineering Materials; ISSN: 1662-9795, Vol. 742, pp 544-551; doi:10.4028/ www.scientific.net/KEM.742.544

Abstract

Multi-material solutions offer numerous benefits producing tailored-made hybrid components with enhanced application-optimized properties contrary to conventional monolithic parts. However, designing of corresponding manufacturing processes is often challenging due to various technical aspects. This paper represents a process route for the manufacturing of a hybrid bevel gear by means of tailored forming technology with a focus on die forging and describes the main challenges within the forming stage. Due to local material-specific properties, uncommon material flow and complex geometry of the final part, an individual forming tool system with a geared die was accurately designed. Besides the forming tool system, the FE-based design of the forging process as well as the necessary material characterisation will be presented. Finally, the initial results of the experimental forging investigations are shown.