Automotive CVT Sheave Development using Complex Forging Processes

  • Authors

    • Wen Kun Peng
    • Sung-Young Park
    https://doi.org/10.14419/ijet.v7i3.24.22812
  • Complex forging, Forming Analysis, CVT, Process Development, Mold
  • Background/Objectives: In this study, we developed a complex forging process to produce a sheave, which is a core part of CVT for automobiles, fabricated prototypes. The existing processes such as hot forging and the MCT machining process have disadvantages including excessive amounts of material cutting, number of processes, and processing time.

    Methods/Statistical analysis: To overcome these shortcomings, in this study, a shape was created using hot forging and the shape was molded into a precision part using cold forging. A complex forging process was developed that enabled maximization of the metallographic density and reduction of material cutting quantity by applying a minimal number of processes. By conducting heat compression and tensile tests of the samples, we identified the physical properties of the material and used the commercial software Deform-3D to conduct a forging analysis.

    Findings: Based on the analysis results, we designed a combined process of hot forging and cold forging and fabricated a mold and pilot products. The fabricated pilot products were evaluated using a metal flow test, an internal defect test, a surface roughness test, etc. According to the evaluation results, no significant defect was observed, and we therefore believe it is adequate for mass production.

    Improvements/Applications: The complex forging method can reduce the use of material by approximately 15% compared with the hot forging and the MCT machining process. Through this study, we established a product development process using a high-precision complex forging technology.

     

     

  • References

    1. [1] H. C. Shin, B. H. Lee, J. H. Jeong, Y. G. Choe, Green auto chassis. GoldenBell, The Third Revised Edition, pp. 45- 48, 2013.

      [2] S. H. Lee, W. J. Chung, E. K. Hong, M. S. Shin, Y. M. Kim, K. D. Ryu, Study on fuel economy improvement of CVT for mid size vehicle. The Korean Society of Automotive Engineers, pp. 238-242, 2012.

      [3] J. Y. Kim, Y. I. Park, F. C. Park, J. M. Lee, On the Development and Application of the Spheriacl CVT. The Korean Society of Mechanical Engineers, pp. 690-695, 2000.

      [4] S. J. Jang, B. Y. Jun, S. M. Jang, M. S. Joun, H. K. Moon, H. S. Sung, M. H. Heo, Development of Hot and Cold Combined Forging Process for a One-Way Clutch Bearing Outer Race. The Korean Society for Technology of Plasticity, pp. 441-444, 2009.

      [5] E. J. Gwak, W. H. Ju, H. S. Moon, E. C. Lee, S. Y. Park, Complex Forging Processes Development of Core Part in One-way Clutch. The Korean Society for Technology of Plasticity, pp. 185-187, 2015.

      [6] M. S. Joun, H. K. Moon, M. C. Lee, D. Y. Suh, Finite Element Analysis of Compound Forging Processes. Korean Society for Precision Engineering, pp. 546-550, 1996.

      [7] J. H. Nam, S. H. Jung, T. W. Jung, Y. S. Lee, Study on New Process for Precision Forging of Helical Gear. The Korean Society for Technology of Plasticity, pp. 107-110, 2010.

      [8] DEFORM User’s Manual V11.0, Scientific Forming Technologies Cooperation, 2016.

  • Downloads

  • How to Cite

    Kun Peng, W., & Park, S.-Y. (2018). Automotive CVT Sheave Development using Complex Forging Processes. International Journal of Engineering & Technology, 7(3.24), 550-556. https://doi.org/10.14419/ijet.v7i3.24.22812