Simulation Of Super Gear With Upsetting-extruding Technology

The net-shape forging is an advanced technology . It may not only lift material utilization from 40% to 70%, but also lift the gear strength over 20% and production efficiency over 40%. Conventional experimental method cost greatly and can't show the fluxion regulation during the deformation. Now as the finite element simulation technique increasingly improved, engineer can carry on the deeper analysis in low cost and high efficiency. This paper discussed the upset—extrusion,which is one kind of the net-shape forging. In Japan, this technology has been used successfully , but in china,this technology is mainly researched in lab now. The largest problem is the punch force increasing sharply at last and metal can not fill up the die entirely. In this paper, the author analysis the reasons, and talk about the settlement means. Then with the well developed numerical simulation software-Msc.superform, the author simulate some forming processes, which include upset-extrusion pre-forging, relief hole, relief axis, restrained hole divided flow, restrained axis divided flow. Then, author analysis some velocity cloud charts, stress cloud charts, force-time relationship charts. Finally the author analyses the effects that the friction factor on the punch force.The imitation results may be helpful to designers. On the base of imitation pattern, designers can carry on the deeper analysis. They can optimize to the main design parameter by means of the imitation in the actual manufacture.