New Unconventional Processes of Plastic Forming of the Internal Toothing of Coupling Spline Sleeves

The article explores the possibility of using the authors’ three new methods of unconventional extrusion of deep hollows to be used for the manufacture of spline sleeves intended for internal toothing couplings. Two invention patents, PL206466 and PL224121, and one patent application, P.416772, were used for this purpose. Numerical computations were made in the Forge®3D program for the conceptual schemes of forming sleeves. The aim of those computations was to determine the extrusion forces and to compare them with the conventional indirect and direct extrusion methods. Then, on models based on the authors’ plastic forming schemes, numerical computations were made, from which the actual energy and force parameters were determined in the form of the relationship of extrusion force versus forming tool path. Also, the degree of fill of the passes, in which spline sleeve toothing is formed, was determined