Design and implementation of hot precision forging die for a spur gear

Download

index.pdf

Date

2007

Author

Maşat, Mehmet

Metadata

Show full item record

Item Usage Stats

285
views

339
downloads

There is a strong need in forging industry to reduce waste of material, improve quality, and reduce cost of forgings. About 30% of the material is wasted during conventional closed-die forging. Therefore, in order to reduce the cost of forged products and to obtain near-net or net shape parts, new forging methods should be applied. Precision forging concept is a cost-effective way to produce net-shape or near-net shape components. In recent years, there has been an increased interest in the production of gears by the net-shape forging technique. This has specific advantages over the traditional manufacturing processes of cutting gears such as hobbing, turning, and grinding including savings on cost and raw material, increased productivity, and gears with higher dynamic properties than conventionally cut ones. In this study, precision forging of a particular spur gear has been investigated. The precision forging die set has been conceptually designed and modeled in a computer aided design environment. The forging process of particular spur gear has been simulated by using a commercially available finite volume program. After the successful simulation results, the prototype die set and the tube-shaped billets were manufactured. The real-life experiments have been realized by using 1000 tons mechanical forging press available in METUBILTIR Research and Application Center Forging Laboratory. The results have been compared with the computer simulations. After the real-life experiments, it has been observed that the conceptual die design is appropriate and near-net shape spur gears are successfully obtained by the proposed precision forging die set.

Subject Keywords

Machine Construction.

URI

http://etd.lib.metu.edu.tr/upload/12608550/index.pdf
https://hdl.handle.net/11511/16734

Collections

Graduate School of Natural and Applied Sciences, Thesis

Suggestions

OpenMETU
Core

Determination of a price index for escalation of building construction costs in Turkey Kahraman, Serhan; Sönmez, Rifat; Department of Civil Engineering (2005) Construction cost indices are developed to measure the degree of price variations in construction material and labor costs. However, each specific type of construction is a combination of unique set of materials and labor. As such, the degree of price variations referring to each specific type of construction shall be measured by specific price indices, in order to achieve more accurate results. In Turkey, Producer Price Index (PPI) published by State Statistics Institute is commonly used for the escalation...
Properties of blended cements with thermally activated kaolin Arikan, Metin; Sobolev, Konstantin; Ertuen, Tomris; Yeginobali, Asim; Turker, Pelin (Elsevier BV, 2009-01-01) Kaolin, one of the materials of major importance for the ceramic and paper industry, is also used in the construction industry as a raw material for the production of white cement clinker and, in the form of metakaolin, as an artificial pozzolanic additive for concrete. Metakaolin is a vital component of high-performance and architectural concrete; however, its application in regular concrete is very limited due to relatively high production costs. This report evaluates the performance of a low-cost metakao...
Determination of relationship between weld quality and mechanical strength in different steels Soylu, Osman Alper; Doyum, Bülent; Department of Mechanical Engineering (2004) This study has been conducted to establish a relation between welding quality and strength in various types of steel. This because specification of quality levels higher or lower than required leads to an increase in manufacturing cost. A procedure has been developed to achieve the above objective. In this procedure EN 25817, EN 288-1 and similar welding and nondestructive testing standards have been taken as a basis. Furthermore, effort has been exerted to ensure that welding is performed in a manner that ...
Laboratory production of calcium sulfoaluminate cements with high industrial waste content Canbek, Ogulcan; Shakouri, Sahra; Erdoğan, Sinan Turhan (Elsevier BV, 2020-02-01) A drawback of conventional calcium sulfoaluminate (CSA) cement production is the use of the costly raw material bauxite as a source of alumina to form the main clinker phase ye'elimite. Replacement of bauxite with industrial wastes can benefit CSA cements economically and environmentally. This study demonstrates the use of high amounts of red mud, a sulfate-rich/high-lime fly ash, and desulfogypsum as raw materials in producing CSA clinkers and cements with better mechanical performances than an all-natural...
A statistical approach to lean construction implementations of construction companies in Turkey Tezel, Bülent Algan; Nielsen, Yasemin; Department of Civil Engineering (2007) One of the major change efforts for the construction industry is lean construction. This thesis analyzes the practices of the construction companies in Turkey from the lean construction perspective. Prior to the analysis in question, requisite information about change in the construction industry, lean thinking and lean construction will be presented. A questionnaire, based on a lean construction model, is used to survey the practices and gather the data for the analysis. Various statistical analysis method...

Citation Formats

M. Maşat, “Design and implementation of hot precision forging die for a spur gear,” M.S. - Master of Science, Middle East Technical University, 2007.