Papers by Author: Xing Hui Han

Abstract: The aim in this paper is to analyze tooth surface contact stress and transmission errors, verify existence of tooth end effect and discuss symmetry of symmetrical bevel gear differential (SBGD), etc. With this aim, a 3D elastic FE model of SBGD is established under the ANSYS software environment and its meshing characteristic is determined. Starting from here, by analyzing stress and circumferential displacement of tooth, the phenomena of stress concentration is acquired; the distribution of tooth surface contact stress is studied; tooth end effect is confirmed; transmission error is assessed. The analysis is ended by assessing the symmetry of SBGD. Research results provide valuable guidelines for the design of SBGD. The developing model method proposed in this paper makes it possible to study other complex gear mechanisms such as planetary gear system.

Abstract: Cold rotary forging is an advanced but very complex incremental metal forming technology with multi-factors coupling interactive effects. The position between the upper die and the workpiece has a significant effect on the cold rotary forging process. In the current work, a 3D elastic-plastic dynamic explicit FE model of cold rotary forging of a cylindrical workpiece is developed under the ABAQUS software environment and its validity has been verified experimentally. On the basis of this reliable 3D FE model, the effects of the position between the upper die and the workpiece on the cold rotary forging process have been thoroughly revealed. The results show that with increasing the distance between the pivot point of the upper die and the centre of the workpiece, the deformation of the workpiece becomes more inhomogeneous and the maximum axial forging force and forging moment gradually increase. The results of this research not only provide valuable guidelines for the installation and adjustment of dies in the cold rotary forging process, but also help to better understand the deformation mechanisms of cold rotary forging.

Abstract: A novel metal plastic forming technology, cold rotary forging with double symmetry rolls, is presented on the basis of cold rotary forging with single roll. A reasonable 3D elastic-plastic dynamic explicit FE model of cold rotary forging with double symmetry rolls is developed under the ABAQUS software environment. Through simulation, the distributions and histories of different field-variables such as stress, strain and force and power parameters are investigated in detail. The research results not only provide an advanced and innovative technology for metal plastic forming, but also help to better understand cold rotary forging with double symmetry rolls.

Abstract: The Conical Ring with Inner Steps (CRIS) is a typical profile ring, which is hard to be formed by ring rolling. Less-profile-filling and shrinking-drawing are the two main defects formed in the rolling process. Through the study of the rolling formability of CRIS with different ratio of height to diameter with the combination of FEM simulation method and experimental method, the main factors that affect the CRIS rolling formability are determined. The CRIS forging is designed. And the FEM simulation and experimental results show that the design method is reasonable.