Tula State University (Tula, Russia):

E. N. Valikov, Dr. Eng., e-mail: valikoven@rambler.ru
V. A. Belyakova, Cand. Eng., e-mail: valentina.belyakova5@yandex.ru
O. I. Boriskin, Dr. Eng., Prof., Head of the Chair of Instrumental and Metrological Systems, Director of Polytechnic Institute

The main task of engineering technology is the manufacture of parts with minimum labor costs and maximum productivity and the metal utilization factor. A promising line in the field of metal processing are plastic deformation methods which provide the signifi cant increase in labor productivity and reduction of technological metal wastes, as well as decrease in complexity of processes and production cost. Plastic deformation of the workpiece in the process of its continuous rolling is accompanied by complex phenomena associated with the surface mixing of the metal, variable friction conditions and a change in the direction of friction forces on the contact surfaces. This results in the occurrence of defects in the form of scales, overlaps and microcracks located in the space and on the heads of teeth. Manufacturing wheel workpieces in detachable dies has the following advantages: 1. Good filling of the die cavity with relatively low degrees of deformation due to the combined extrusion. 2. Fabrication of workpieces without stamping slopes and waste metal in flash during stamping in the closed volume. 3. The possibility to obtain the configuration and dimensions of the workpieces, as close as possible to the finished part due to the split design of the die. 4. The possibility to introduce a semihot stamping of cylindrical gear wheels with the formed toothing rim without significant capital expenditures thanks to the universal stamping equipment. To expand the field of application of wheels made of the workpieces with formed teeth is possible only if a productive method for finishing processing of teeth with high (by 3–4 degrees) correcting capabilities is used which allows excluding the preliminary gearcutting (before finishing processing) out of the technological process. Such methods can be fine cutting by carbide cutter heads with a zero profi le angle and shaving-rolling.
The results of the research pro ject are published with the financial support of Tula State University within the framework of the scientific project № 2017-16.

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