الفهرس 
Chapter 1: Introduction And Literature ReviewOnly 14 pages are availabe for public view
 |  | from | 93 |  |  |
| | | from | 93 | | |
Abstract
The sleeves with external splines have an increased attention due to its use as power transmission parts in automotive, aviation, airspace, and machining equipment such as lathe, milling, and all equipment that have gear box. The manufacturing process of these sleeves by machining is expensive due to the consumed power, use of a special tool, and the material loss in machining. A new tool is proposed here to form the sleeves with external splines in one shoot. The new tool consists of a die with splines opposite to the required splines at its inner face. This die has a support for the specimen at the lower side and the specimen which has a longitudinal hole is fixed inside the die. A ball with a diameter larger than the specimen inner diameter by double the forming depth is forced inside the specimen hole to take the required sleeve shape by compelling the specimen inside the die cavities. The used specimen material was lead. The process was performed on the universal testing machine. A mathematical model was formulated to calculate the required forming force. The model is depending on the process dynamics and the contact area between the tool and the specimen. The model result found to give a maximum forming force of about 8 tons which means the process can be performed on the universal testing machine with 50-ton maximum load. The universal testing machine also has a computer to save the process data during the performing of the process to know the force trend along the whole process. The study started with accomplish the success of the proposed tool. Then, study the effect of process parameters on the load and the product properties. The study parameters were; forming depth of 2.5, 5, 7.5, 10, and 12.5 mm, forming ball speed of 5, 15, 25, and 35 mm/min, the forming ball diameter of 15, 20, 25, 30, and 35 mm, specimen inner diameter of 10, 15, 20, and 25 mm. the used specimen of lead has a diameter of 44 mm. The results of the study were the success of the tool and the effect of the studied parameters on the process load and product properties was discussed. Also, the comparison between the mathematical model results and the experimental results was explained.