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熱擠製鋁合金6061三階齒輪之研究：有限體積模擬與實驗的比較

為了解決Crack tooth的問題，作者PAVAN SAI PAGADALA 這樣論述：

The study introduces a novel technique, bidirectional hot extrusion and uses a selective laser melting (SLM) machine with Inconel 718 alloy to additive manufacturing of a helical-spur-helical three-stage gear. An experimental investigation is carried out on Aluminum 6061 alloy by performing the Ten

sile test on the cylindrical specimen machined based on ASTM E-8M standard to compare the estimated results with the available library data. To determine the effectiveness of the introduced techniques, firstly a computer-based design followed by analysis is carried out with the help of MSC Simufact

forming and MSC Simufact additive. The analysis includes the Finite Volume Method (FVM) for the triple gear and the Powder Bed Fusion (PBF) technique for gear die. Convergence test has been performed using the FVM with Aluminum 6061 as the material based on varying mesh element size. Simulation is e

xecuted at three different temperatures 350°C, 400°C, 450°C, and numerous attempts were made to determine the optimal time and velocity for obtaining a more favorable gear profile and the computation time. With a constant optimal time of 10s and varying the mesh element size between 0.5 to 1.6 mm wi

th the input velocity of 1.75, 2.0 & 2.25 mm/s, it is observed that the die filling rate is very accurate, and crack formation on the tooth bed is minimum. The input parameters of PBF in Simufact additive such as scan velocity, laser power, beam width, and layer thickness are optimized to evaluate t

he residual stresses and distortions formed in the fabrication of gear dies which yielded satisfactory results. IFUM (Institute for forming technology and forming machines) model is employed to evaluate the material flow rate and underfilling of the gear tooth. Considering the simulation results, ex

periments are performed to fabricate the gear die using the SLM technique and the triple-gear using monodirectional hot extrusion (due to unavailability of required bidirectional hot extrusion machine setup). Surface machining is performed to the gear die to obtain a favorable gear profile closely m

atching the simulation results.