Virtue CAE Research Of Gear Cold Forging

Gears are used widely in automobile, ship and other machines as the movement and power transfer parts. The traditional manufacturing technique of gears, the metal cutting method, has many disadvantages, such has low use rate of material, low productivity, high production cost, and so on. 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 gear cold forging, which is one kind of the net-shape forging. In Japan and German, 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.Superforging, the author simulate some forming process, which include relief hole, relief axis, restrained hole divided flow, restrained axis divided flow. Then, author analysis some effective strain rate, contact pressure, material flow and temperature chart.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 try means of the imitation in the actual manufacture.