Theory And Application Of Divided Flow Extrusion For Gears Part

Cold extrusion is a new precise plastic forming technology developed these years in the word. It would become the method to machine complicated part in the future because of its advantages: high precision, high quality, low consumption, low cost, large batch and so on. Cold extrusion is used on the gear can change the extensive character which the traditional forging has. The divided flow extrusion has many advantages: material saving, energy saving, high efficiency and low cost. The part has high decision, good surface quality, rational metal streamline, high erosion resistance and wear-ability and high flexure strength, Fatigue life.In this paper, based on the divided flow extrusion, by changing the aperture size to analyze the forming resistance and the filling effect of the metal. The use of finite element analysis software DEFORM to simulate the forming process of the finite element numerical simulation, by analyzing the simulation results to study the metal forming process in the flow rule, as well as the forming process on the impact of mold-related factors, the guidance of mold design, manufacture and use. Verification experiment to validate the use of the principle of the theory and simulation results, and to identify diameter and the relationship between the original blank.With the increase in diameter, the forming resistance was significantly decreased, increased diversion of materials; the filling of materials was reducing. Diameter size of the cold extrusion has a great impact. The optimization diameter is difficult to determine, as diameter increase, although it will greatly reduce the forming pressure, but because of material diverted too much filling will cause dissatisfaction. The small diameter, resulting in the deformation force, reducing die life.According to the research result, the principle of divided flow extrusion for automotive drive shaft with gear in the cold extrusion process and reduce the deformation resistance, to overcome the equipment needs of large-tonnage, resulting in improved production efficiency and achieve the production of precision parts of complex and high quality, efficient, low-cost objectives.