Modelling and experimental research in hot precision forging of shaft gear

Abstract

Abstract. In this paper, a hot forging die set is designed for a shaft gear. A finite element software DEFORM was employed to simulate the hot forging process. The forming parameter range was determined and the forging force was predicted. The metal flow law in hot forging processes was studied using metal flow analysis and point tracking analysis. The metal flow law was further analysed through finite element simulations and precision forging experiments. The accuracy of hot formed gears is analysed and the deviation of the tooth profile reaches the 8th grade, which meet the defined requirement. The pitch cumulative deviation of the forged part is low enough for practical applications.

Modelling and Simulation of the Plastic Flows in Metal

“…It is easy to see that direction of metal flow during deformation can be approximated by a hyperbola [25], just like flow of metal chips during cutting, if we analyse the macrostructure of the metal and direction of the fibres in part after forming processes [26]. At the same time, variety of metal forming operations [27] from dividing operations and punching to multi-strand stamping including the tools used in this case raise issue of finding an approximating flow curve for each operation individually.…”