VL Star Set Forming Process and Mold Design
The VL star set has a very unique and somehow complex forming process. With cold forging being the most recommended forming method rt, there are several things that must be gotten right. In this guide, we will look at the forming process of the VL star set and the mold design.
The VL star set consists of four main parts – the star-shaped sleeve, ball cage, cage, and the steel ball. Because of the V-shape of the sleeve’s adjacent channels as well as the down straight channel shape, it is hard to use the ordinary up and down stroke forging process to make the mold structure. Let’s look at the cold forging process development and mold design for the VL star set.
VL Star Set Process Design
The process of forming the VL start set is straightforward. It has seven main steps that you must pass through to get a high-quality product. The seven stages include blanking – balled de-ignition – projectile – phosphorus saponification – cold forging– drilling – machining. We will look majorly at the forming of the star sleeves and ramps, which ends at forging. The major difference between the VL star sleeves and the typical star sleeves is the mold structure.
To get precise V-shaped channels, the mold structure must offer the best precision features. Do note that the ‘V’ channels are cold-forged while the end face and the inner aperture are machined. But we are going to look at the cold forging aspect of forming the VL star set. Let’s check the mold design.
VL Star Set Mode Design
The making of the VL star set mold is not a very complex process. Despite the V-shapes looking intricate, it is very easy to get the mold done in just several steps. As mentioned above, the material to form the mold must undergo several stages, which are the blanking, de-ignition, projectile, phosphorus saponification, and then forging.
The extrusion of the ‘V’-shaped ramp on the blank is the most delicate process. The ramps are formed such as one piece of mold structure is used. The upper and lower roll molds, ingress directly without interfering with the mold cavity. This means the forming of the VL star set takes the form of blank withdrawal.
When forming the VL star set, the molds for all the six ramps are used in the blank’s deformation. When the material is returned, the mold forming the ramps is also returned without interfering with the blanks. Therefore, the six oblique rollers are easily designed using components mold structure.
In making the six ramps’ mold, both the lower and upper strokes are needed for proper cold forging. The upper die is the one that makes the six ramp rollers molds close first using the down motion. The lower stroke or lower punch work is to return the upper die and the ramp roller mold. That’s how the cold forging technique simply works to make the six ramps.
Do note that the six ramp roller molds are designed depending on the VL star set’s size. If the outer circle is large, then the roller molds must be made larger. The rollers’ arrangement has three in the same direction and the other three in the opposite direction. That’s simply how the “V” shapes with different directions are formed.
Simulation Analysis
For the VL star set’s quality and effectiveness, it is important to carry out finite simulation analysis. The 20CrMnTi material is used for the 3D finite meta-simulation. The analysis helps to check the stress distribution at the ramps. If the stress is evenly distributed evenly among the six ramps, then the product is good for use. The forge software is very critical in this analysis.
In conclusion, the VL star set forming process can be made pretty simple with cold forging. The forming of the mold to produce the ramps is the most intricate process. In addition to that, the machining of other parts of the VL star set is crucial for quality products. The finite mega simulation process is very crucial to ensure quality and efficient products. If you are interested in cold forging, you can consult Cxin Forging.