Study on forming condition and tool of flywheel by using flow forming process

摘要

Many plastic forming methods, such as cold and hot forging, hydroforming, deep drawing,nextrusion, rolling and spinning have been researched to develop metal plastic formingntechniques. Still, no appropriate tool exists for the process and for the required geometry innmanufacturing, especially in the forming fields. Thus, through this study we examinednexhaustively flow forming and an appropriate material for extreme plastic deformation and flownstress. To this end, we focused on volume increase per unit length against the spinning process, anflow forming method, where the most important consideration is probably to sustain the metal flownas well as to prevent metal fold in the forming process. We chose a gear part of the flywheel of annautomotive engine for the study model which consists of a separate plate and gear with differentnthicknesses, welded for assembling two parts. The rim of the squared section, thickened for gearnmachining on the plate edge, was manufactured through the flow forming method. Because thisnmethod does not allow the required geometry when forming, incremental forming was applied fornflow forming. In addition, the geometry and process conditions of the forming tool based on thenforming features were investigated in each step. As results of the present study, the optimisednforming conditions for gear machining considering the thickness of the outer edge of the flywheelnwere evaluated using comparable tests, with various groove depths, angles and processnconditions in each step of the manufacture of the forming roller.