Finite element analysis and simulation for cold precision forging of a helical gear
来源期刊：中南大学学报(英文版)2012年第12期
论文作者：FENG Wei (冯玮) HUA Lin(华林) HAN Xing-hui(韩星会)
文章页码：3369 - 3377
Key words：helical gear; cold precision forging; finite element simulation; relief-hole principle
Abstract: To investigate the effects of billet geometry on the cold precision forging process of a helical gear, six different billet geometries were designed utilizing the relief-hole principle. and the influences of the billet geometry on the forming load and the deformation uniformity were analyzed by three-dimensional (3D) finite element method (FEM) under the commercial software DEFORM 3D. The billet geometry was optimized to meet lower forming load and better deformation uniformity requirement. Deformation mechanism was studied through the distribution of flow velocity field and effective strain field. The forging experiments of the helical gear were successfully performed using lead material as a model material under the same process conditions used in the FE simulations. The results show that the forming load decreases as the diameter of relief-hole d0 increases, but the effect of d0 on the deformation uniformity is very complicated. The forming load is lower and the deformation is more uniform when d0 is 10 mm.
FENG Wei (冯玮)1, HUA Lin(华林) 1,2, HAN Xing-hui(韩星会)2
(1. School of Materials Science and Engineering, Wuhan University of Technology, Wuhan 430070, China
2. Hubei Key Laboratory of Advanced Technology of Automotive Parts,
School of Automotive Engineering, Wuhan University of Technology, Wuhan 430070, China)
Abstract:To investigate the effects of billet geometry on the cold precision forging process of a helical gear, six different billet geometries were designed utilizing the relief-hole principle. and the influences of the billet geometry on the forming load and the deformation uniformity were analyzed by three-dimensional (3D) finite element method (FEM) under the commercial software DEFORM 3D. The billet geometry was optimized to meet lower forming load and better deformation uniformity requirement. Deformation mechanism was studied through the distribution of flow velocity field and effective strain field. The forging experiments of the helical gear were successfully performed using lead material as a model material under the same process conditions used in the FE simulations. The results show that the forming load decreases as the diameter of relief-hole d0 increases, but the effect of d0 on the deformation uniformity is very complicated. The forming load is lower and the deformation is more uniform when d0 is 10 mm.
Key words:helical gear; cold precision forging; finite element simulation; relief-hole principle
