Steel Gear Of Synchronizer Form Technics And Reserch Of Experiment

Steel gear of synchronizer is an asymmetric ring thin wall part with several spline teeth. It is mainly used in gearshift. It is an issue for forging process and mould design because its complex shape which results in insufficient filling, folding and so on. With the development of auto industry, a lot of gears of synchronizer are needed, but it is difficult to get a good satisfactory product in our country.The key problems of the copper gear which is used in heavy-duty car and big-bus during the forging process are discussed in this paper. The forming of gear is featured of general forging and precision forging. The teeth are not fully filled usually because of its small radius due to its involutes profile. Meanwhile the stress of mould during forging is complex, especially in the bottom of the tooth, the radius is so small that the flow of the metal is difficult, thus the life time of the mould is low. On the other hand, the gear won't be manufactured any more so it is very important to control the processing parameters.In the paper the forming of the gear is analyzed based on numerical simulation, which provides evidence for processing optimization and mould modifying to get an accurate blank. In addition, the one-step forming processing for the copper gear is analyzed, and the flow of the material, forming process, flaw prediction and the optimization of the mould structure is studied as well. Besides these, according to the two typical failure mode—early crack and wear deformation, the life time of the die is studied based on the stress.The cycle life of new product development is reduced greatly by forming process analyzing and flaw prediction of the gear which provide evidence for manufacturing the same kind of product.