Precision Forging Process Design Of Transmission Gear-Shaft

Precision forging features the improvement of production efficiency and reduction of manufacturing cost which has been widely used globally, especially in the automotive industry. As our country set out to the development of precision forging comparatively later than foreign countries and automotive industry progressed slowly which could contribute to the application of precision forging, precision forging technology dropped behind so that process design was planned mostly relying on engineers'experience and verified by testing. With the rapid development of automotive industry, advanced technology needs to be utilized to analyze and evaluate process on the basis of conventional design and analysis. Finite element numerical simulation is one of the better approaches.On the basis of company production demand, this dissertation discusses the transmission gear-shaft precision forging process, delves into each contributing factors of precision forging, introduces conventional experience and principle of process design and depicts the basic principle of rigid and plastic finite element approach by introducing finite element numerical simulation software– DEFORM. With respect to the gear-shaft of one certain transmission, precision forged parts, process flow and mold are elaborately designed and forming pressure on shaft cold extrusion operations are calculated both theoretically and experientially. While numerical simulation using DEFORM comparison with product value are conducted on each operation, we conclude that through numerical simulation approach, the deformation rule of metal during precision forging can be obtained so as to accurately forecast part quality and forming pressure, providing basis for analysis and evaluation of process.Finite element numerical simulation enables to impact multiple factors of process, ie. predict the damage on forming parts, generating fixed value of stress and strain distribution and saving testing time and cost, and provide technical foundation for process design optimization and parameter adjustment.