Study On Precision Forging Of Steel Synchronizer Gear Ring

The technique of precision forming is a kind of new process having little or no cutting, with the development of modernized extensive production, after the World War II. That means, the part only need a little process or no process after forming (near net shape technique or net shape technique), then can be used as mechanical component. It improved the traditional technique of semiproduct forming, made it shape from coarse to the superior quality, efficient, high accuracy, light quantizing, low cost, and harmless.The mechanical component after forming has the accurate appearance, high accuracy of size and form, and the good rough degree in surface. This technique includes near net shape cast forming, precision plasticity forming, accurate connection, accurate heat treatment, the surface modify professional field etc. The structure and performance of gear can be improved effectively through this process. The process can make material depressed stress in three directions. So it can attenuate crvstal grains, improve the density and decrease microcosmic defects. If steel synchronizer gear ring is used precision forging, it also can make metallic fibre streamline of teeth more continuous and symmetrical, and lead to the improvement of mechanical performance of gear. The precision of gear shape can come to a very high level. The workpiece needs only a little of machining before heat treatment. The process increases productivity rate and use ratio of materials, decreases the cost of production. Therefore the competing ability of gears is improved greatly.During recent years, with the rapid development of computer technology, the technology of precision forging has achieved great progresses. In this research a kind of steel synchronizer gear ring was introduced, whose model was made by the CAD technology. The forming process of synchronizer gear ring was simulated by FEM software. The transformations of the fields during the process of metal forming were investigated, the tendency of metallic flow was forecasted, and the rules how various items affect the forming load, metallic flow, the life of dies were discovered. The factors include the different structures of male and female die, web thickness, the distance between web and big-end face of gear, etc. And the most suitable die structure, web thickness and distance were made certain. A proper warm forging process and a die-set based on 630-ton rub press were designed according to the result of FEM simulation. Finally some experiments were made. Contrasting the simulation result with the...