Numerical Simulation Research On Cold Forging Of Spur Gear

Gears are important drive parts applied widely in the automobile , ship and other mechanical industries. The traditional manufacturing technique of gears, the metal cutting method, has many disadvantages, such as low material utilization, low productivity,high cost etc. The precision plastic forming technology of spur gear is an advanced technology. It may lift material utilization over 30%, strength over 20% and production efficiency over 40%. Because the corner of gears filled difficultly and big forming force, the cold precise forging of spur gears isn't put into the industrializaed application. The new forming process is explored for increasing the forming quality and reducing the cost, which is important to develop our mechanical industries.This paper deals with numerical simulation of cold forging forming of spur gear.The method, which coupled hole divided-flow with floating-die, can forming on-gauge spur gears directly. It not only ensures the filled gear teeth, but also reduces the forming force.The spur gear is built parametrically with 3D CAD software Unigraphics NX. Adopting 3D finite element simulation software DEFORM-3D, the cold forging forming of spur gears is simulated by three dimensional rigid plastic finite elemental method. The effective stress distribution, the effective strain distribution, the velocity distribution, the displacement distribution and the load-stroke curve of the whole process are got. By finite element analysis, metal flow behaviors and deformation mechanics of spur gears are obtained. Selecting friction coefficient, forming velocity, radius of die corner, diameter of divided-flow hole, the cold forging process in spur gear is simulated for the goal of developing the forming quality and reducing the forming force, then the optimum matching parameters are defined, and accordingly the mould of cold forging is designed ,which can provide some reference for subsequent research on forming .