The Forging And Mould Process Improvement Of Synchronizer Gear Ring

This paper takes a type automobile synchronizer gear ring as the research object, the finite element analysis is carried out on the existing mold. Aiming at the problems in the analysis, the structural is improved. In order to solve the problems that exists in the actual production.Because manganese brass mechanical strength and abrasion resistance is more satisfy than other materials in the use requirements, therefore it is widely used in synchronous ring manufacturing. But the temperature range of the application of manganese brass is narrow, meanwhile, the synchronizer gear ring dedendum fillet is small, the blank is easy to occur uneven stress distribution and some small crack in the process of forging. And as a large scale production, the low utilization rate of materials not only increases the difficulty in other working processes, but also causes the high production cost. So this paper combines the finite element simulation with the production, and finite element simulation is used in forging process and die of the synchronous ring. The main work of this paper is as below:The improvement of synchronous gear ring female die and mandril. Through the empirical formula, the influence of thermal expansion and elastic deformation is brought into the improvement of the tooth ring female die cavity, and the precision of the forging is improved; at the same time, the hot forging female die and mandrel are improved, the blank size is decreasing, thus reducing the processing cost and difficulty.Optimization of the synchronous gear ring process parameters based on the single factor experiment method. Using DEFORM software to simulate the forging process of gear ring, the blank size is optimized and the material utilization ratio is improved. To load, equivalent damage capacity and material as the goal, the process parameters are optimized. On the uneven stress distribution and material damage existing in the simulation, the influence of male die pressing speed, initial temperature and friction coefficient is analysed, and then the optimal forming parameters are obtained.Making a finite element simulation of different hardness, initial temperature, mold pressing rate and friction coefficient on die wear, the influence of various process parameters on the wear of the mould is summarized.This study is of great significance to the actual production, the improved mold single wear is reduced, life is prolonged, the improved saves 19.9% material than before, the cost is saved, and the difficulty of subsequent processing is reduced.