Manufacturing Technology 2025, 25(4):460-468 | DOI: 10.21062/mft.2025.049

Novel Multi Levels Tool Based on Rotating Ballizing Technique to Manufacturing the Externally Toothed Components an Experimental Study

Eman S. M. Abd-Elhalim ORCID...1, Emad A. Fahmy ORCID...2, Mohamed N. El-Sheikh ORCID...2, Ahmed M.I. Abu-Oqail ORCID...2, Hammad T. Elmetwally ORCID...2, Ayman Ali Abd-Eltwab ORCID...3
1 Mechanical Eng. Dep., Faculty of Engineering, Assiut University, Assiut, Egypt
2 Mechanical Department, Faculty of Technology and Education, Beni-Suef University, Beni-Suef 62511, Egypt
3 Associate Professor, Mechanical Engineering Department, Faculty of Engineering, Beni-Suef University, Beni-Suef 62511, Egypt

Externally toothed components have a very crucial and essential role in all areas of production and manufacturing because they function as away of transmitting motion, energy, and power in all indus-trial applications, such asmodes of transportation, aviation, aerospace, equipment, and operating machines like lathes and milling. All machines have a gear box. Therefore, it is receiving increasing attention. This research presents a new multi-stage rotary ballizing technology for producing toothed parts in one stroke. This process has been investigated experimentally. The parameters that were ex-amined experimentally was at the optimal conditions for single stage ballizing were: die rotation speed of 315 rpm; Axial feed rate, 0.13, mm/rev; The interference (cross in-feed) between the balls and the tubular specimen of 5.5 and 6.5 mm is formed by three stages of ball forming of graduated outer diameters and fixed on a single mandrel; Initial tube thickness is 7 and 8 mm. The effect of these parameters on the forming load, filling ratio and quality of the formed part was studied. The finding sindicated that the seideal variables influence the forming load, tooth filling proportion, and product quality. Experimental results proved the success of this novel technique to form toothed tubular components

Keywords: Multi-stage ballizing, Externally-toothed parts, Ball spinning, Ballizing, Mathematical model, Shear spinning, Coining, Spinning, Gears, Process parameters
Grants and funding:

The authors would like to extend acknowledgement to their research institutions Faculty of Engineering, Faculty of Technology and Education Beni-Suef University and Mechanical Eng. Dep., Faculty of Engineering, Assiut University, Assiut, Egypt, that provided support for this work

Received: April 25, 2025; Revised: September 19, 2025; Accepted: September 24, 2025; Prepublished online: October 22, 2025; Published: November 11, 2025  Show citation

ACS AIP APA ASA Harvard Chicago IEEE ISO690 MLA NLM Turabian Vancouver
Abd-Elhalim ESM, Fahmy EA, El-Sheikh MN, Abu-Oqail AMI, Elmetwally HT, Abd-Eltwab AA. Novel Multi Levels Tool Based on Rotating Ballizing Technique to Manufacturing the Externally Toothed Components an Experimental Study. Manufacturing Technology. 2025;25(4):460-468. doi: 10.21062/mft.2025.049.
Share...
Download citation
  • BibTeX (.bib)
  • Bookends (.ris)
  • EasyBib (.ris)
  • EndNote (.enw)
  • EndNote 8 (.xml)
  • ISI WoS (.isi)
  • Medlars (.medlars)
  • Mendeley (.ris)
  • MODS (.xml)
  • Papers (.ris)
  • RefWorks (.txt)
  • RefManager (.ris)
  • RIS (.ris)
  • MS Word (.xml)
  • Zotero (.ris)
    • Open full article

    References

    1. HAGHSHENAS, M., JHAVER, M., KLASSEN, R. J., & WOOD, J. T. (2011). Plastic strain dis-tribution during splined-mandrel flow forming. Materials & Design, 32(6), 3629-3636 Go to original source...
    2. JIANG, S. Y., ZHENG, Y. F., REN, Z. Y., & LI, C. F. (2009). Multi-pass spinning of thin-walled tubular part with longitudinal inner ribs. Transactions of Nonferrous Metals Society of China, 19(1), 215-221 Go to original source...
    3. MISCANDLON, J., TUFFS, M., HALLIDAY, S. T., & CONWAY, A. (2018). Effects of flow forming parameters on dimensional accuracy in Cr-Mo-V steel tubes. Procedia Manufacturing, 15, 1215-1223 Go to original source...
    4. LI, Y., XU, Z., TANG, Y., & ZENG, Z. (2010). Forming characteristics analysis of the cross-section of axially inner grooved copper tube. The International Journal of Advanced Manufacturing Technology, 47, 1023-1031 Go to original source...
    5. MA, Z. E. (1993). Optimal angle of attack in tube spinning. Journal of Materials Processing Technology, 37(1-4), 217-224 Go to original source...
    6. LI, M., ZHANG, S. H., & KANG, D. (2005). Research on selecting working angle in ball spin-ning. International journal of vehicle design, 39(1-2), 73-79 Go to original source...
    7. JIANG, S., REN, Z., LI, C., & XUE, K. (2009). Role of ball size in backward ball spinning of thin-walled tubular part with longitudinal inner ribs. Journal of materials processing technology, 209(4), 2167-2174 Go to original source...
    8. ROTARESCU, M. I. (1995). A theoretical analysis of tube spinning using balls. Journal of materials processing technology, 54(1-4), 224-229 Go to original source...
    9. ZHANG, Y. Q., JIANG, S. Y., ZHENG, Y. F., & ZHAO, L. H. (2010). Finite element simulation of backward ball spinning of thin-walled tube with longitudinal inner ribs. Advanced Materials Research, 97, 111-115 Go to original source...
    10. CHUNJIANG, Z., JIE, X., XIAODONG, H., LIANYUN, J., JIEFENG, L., & CHEN, W. (2017). The analytical model of ball-spinning force for processing an annular groove on the inner wall of a steel tube. The International Journal of Advanced Manufacturing Technology, 91, 4183-4190 Go to original source...
    11. ZENG, X., FAN, X. G., LI, H. W., ZHAN, M., ZHANG, H. R., WU, K. Q., ... & LI, S. H. (2020). Die filling mechanism in flow forming of thin-walled tubular parts with cross inner ribs. Journal of Manufacturing Processes, 58, 832-844 Go to original source...
    12. KUSS, M., & BUCHMAYR, B. (2016). Damage minimised ball spinning process design. Journal of materials processing technology, 234, 10-17 Go to original source...
    13. ZHANG, G. L., ZHANG, S. H., LI, B., & ZHANG, H. Q. (2007). Analysis on folding defects of inner grooved copper tubes during ball spin forming. Journal of materials processing technology, 184(1-3), 393-400 Go to original source...
    14. SHUYONG, J., & ZHENGYI, R. (2008). Analysis of mechanics in ball spinning of thin-walled tube. Chin J Mech Eng, 21(1), 25-30 Go to original source...
    15. AHMED, K. I. (2011). A new ball set for tube spinning of thin-walled tubular parts with longitu-dinal inner ribs. JES. Journal of Engineering Sciences, 39(1), 15-32 Go to original source...
    16. KASSAR, M., AHMED, K., ELSHEIKH, M., & EL-ABDEN, S. (2022). Tube Spinning Using Functionally Graded Ballizing. Available SSRN, 3977528 Go to original source...
    17. EDRIYS, I. I., & FATTOUH, M. (2013). Characteristics of Finished Holes By Ballizing Process. ERJ. Engineering Research Journal, 36(4), 403-415 Go to original source...
    18. LAI, M. O., & NEE, A. Y. C. (1989). The effect of several finishing processes on the fatigue re-sistance of hole surfaces Go to original source...
    19. DYL, T. (2017). The numerical and experimental analysis of ballizing process of steel tubes. Ar-chives of Metallurgy and Materials, 62(2A), 807-814 Go to original source...
    20. DYL, T. (2017). The Numerical Analysis of the Ballizing Process. Scientific Journal of Gdynia Mari-time University, (100), 63-75
    21. FATTOUH, M. (1989). Some investigations on the ballizing process. Wear, 134(2), 209-219 Go to original source...
    22. EL-ABDEN, S. Z., ABDEL-RAHMAN, M., & MOHAMED, F. A. (2002). Finishing of non-ferrous internal surfaces using ballizing technique. Journal of materials processing technology, 124(1-2), 144-152 Go to original source...
    23. KIM, N., KIM, H., & JIN, K. (2013). Minimizing the axial force and the material build-up in the tube flow forming process. International Journal of precision engineering and manufacturing, 14, 259-266 Go to original source...
    24. NEE, A. Y. C., & VENKATESH, V. C. (1983). A mathematical analysis of the ball-burnishing process. CIRP annals, 32(1), 201-204 Go to original source...
    25. NEE, A. Y. C., & VENKATESH, V. C. (1984). Dry and lubricated ballizing. Tribology international, 17(1), 25-29 Go to original source...
    26. UPADHYAY, P. K., JOSHI, H., & AGARWAL, P. Evaluation of Different Forces for Super Finishing the Internal Surface of Ballizing process
    27. NEE, A. Y. C., & VENKATESH, V. C. (1982). Bore finishing-the ballizing process. Journal of Mechanical Working Technology, 6(2-3), 215-226 Go to original source...
    28. KHODADADI, M., KHALILI, K., & ASHRAFI, A. (2020). Studying the effective parameters on teeth height in internal gear flowforming process. International Journal of Engineering, 33(12), 2563-2571 Go to original source...
    29. MAXIMOV, J. T., DUNCHEVA, G. V., & AMUDJEV, I. M. (2013). A novel method and tool which enhance the fatigue life of structural components with fastener holes. Engineering Failure Analysis, 31, 132-143 Go to original source...
    30. UPADHYAY<sup>1</sup>, P. K., AGARWAL, P., & ANSARI, A. Discussion and Analysis of Ball Rolling (Ballizing) Process with Elastic and Plastic Deformation between Ball and Material
    31. ABD-ELTWAB, A. A., EL-ABDEN, S. Z., AHMED, K. I., EL-SHEIKH, M. N., & ABDEL-MAGIED, R. K. (2017). An investigation into forming internally-spline sleeves by ball spinning. International Journal of Mechanical Sciences, 134, 399-410 Go to original source...
    32. AYMAN ALI ABD-ELTWAB, ESSAM KHALAF SAIED, AHMED MOHAMED ATIA, NOUBY M. GHAZALY, A.A. Gomaa, Karim Mohamed Atia (2024). Investigation of externally toothed parts forming using ballizing technique. Results in Materials, 24 (2024) 100640, https://doi.org/10.1016/j.rinma.2024.100640 Go to original source...
    33. BHATT, R. J., & RAVAL, H. K. (2018). In situ investigations on forces and power consumption during flow forming process. Journal of Mechanical Science and Technology, 32, 1307-1315 Go to original source...
    34. DROGE KRAFTE, K., und Material fluss beim Drucken, T.H. Stuttgart, (1954)
    35. HAYAMA M., "Theoretical Study of Tube Spinning", Bull. Fac. Eng. Yokohama Univ., Vol. 15, pp. 33-47, (1966)
    36. RAGAB K. ABDEL-MAGIED, EMAD A. FAHMY, A. EL-SAYED M. HASSAN, MOHAMED N. EL-SHEIKH, ESSAM K. SAIED AND AYMAN A. ABD-ELTWAB, "An Investigation into Forming Externally Toothed Parts using Novel Tool based on Rotary Forging Technique." International Journal of Advanced Science and Technology, ISSN: 2005-4238 IJAST, Vol. 29, No.03, (2020), pp. 2194-2206
    37. ABD-ELTWAB, A.A., HELAL, G.I., EL-SHEIKH, M.N., SAIED, E.K., & ATIA, A.M. (2023). An Investigation into Conventional Spinning Process Using Ball Shaped Rollers as Forming Tool. Manufacturing Technology Journal, 23(6), 788-800. doi: 10.21062/mft.2023.084 Go to original source...
    38. ABD-ELTWAB, A.A., ELSYED AYOUB, W., EL-SHEIKH, M.N., SAIED, E.K., GHAZALY, N.M., & GOMAA, A.A. (2024). An Investigation into Forming of Gears Using Rotary Forging Process. Manufacturing Technology Journal, 24(4), 539-551. doi:10.21062/mft.2024.068 Go to original source...
    39. ABD-ELTWAB, A.A., HAMDY, K., ELSHEIKH, A., SAIED, E.K., GHAZALY, N.M., & GOMAA, A.A. (2024), An investigation into production of double wall tube using squeeze Bal-lizing technique. Journal of Manufacturing Processes, 127 (2024) 545-558. https://doi.org/10.1016/j.jmapro.2024.08.005 Go to original source...

    This is an open access article distributed under the terms of the Attribution-NonCommercial 4.0 International License (CC BY-NC 4.0), which permits non-comercial use, distribution, and reproduction in any medium, provided the original publication is properly cited. No use, distribution or reproduction is permitted which does not comply with these terms.


    Return to the content