Numerical Simulation Research Of Sector Gear Shaft Hot Forging

As the foundation of the automobile manufacturing industry, auto parts are the key technology to support the scientific development of the automobile industry. The large difference of manufacturing technology between China and foreign countries in the field of high-end commercial vehicles lies in the deficiency of key parts design and manufacturing technology which is a serious constrain on the development of China’s national automobile industry. Automobile sector gear shaft is mainly applied to the steering system of high-end commercial vehicles, which are the important parts of the steering system and the safe core parts. The research on the precision forming technology of sector gear shaft is of great significance for improving the productivity of automotive parts and the precision of parts as well as reducing production costs.The failure modes of die mainly include wear, fracture and plastic deformation, although the die has a variety of modes with different working conditions and damages. The surface hardness and the carrying capacity of hot forging die can be undermined by the heat load; furthermore, the mechanical load can accelerate the damage. With the co-combination of the heat load and the mechanical load, the damage of hot forging die has a severe wear. The terrible working condition has a direct effect on the service life of hot forging die.This paper conducts a study of the modeling method of numerical simulation finite element in sector gear shaft hot forging process, solves the problems of craftwork analysis, three-dimensional design of the mold and finite element modeling technology for sector gear shaft hot forging, etc. What’s more, the papers develops numerical model in the sector gear shaft hot forging process. The paper also proposes different initial design schemes of the blank and select reasonable size of the blank through the isothermal forging numerical simulation. Thermal coupling finite element simulation model in sector gear shaft hot forging process is developed using O62.5mm x370mm of blank. In addition, distribution rule of forging load, stress field, strain field and mold temperature field in the sector gear shaft hot forging process is achieved by the model. This paper analyzes different forms of failure and wear of hot forging die. By using the calibrated Archard wear model considering the temperature variation, make the secondary development of Deform3d software. Wear model will be embedded in the software through the user subroutine, so as to realize numerical analysis of mould wear in the gear shaft hot forging process. This paper also conducts simulation study of the iMPact of initial temperature of die, forging speed, friction factor and other process parameters on the mould wear, so as to get the relationship between the process parameters and hot die wear amount, and choose the wear and gear shaft tooth size tolerance as the evaluation standard of die life, so as to estimate the die life. Propose measures to improve the wear life of gear shaft hot forging die based on the numerical simulation analysis, so as to propose scientific guidance for sector gear shaft process and die optimization design.