Analysis of simulated forming load for final forging of half shaft gear

From the load stroke curve, it can be seen that the load change in the whole deformation process can be roughly divided into three stages: in the first stage, the metal is basically not deformed, the load is very small, and the rise is very slow; In the second stage, the metal begins to fill the tooth cavity, and the flow resistance of the metal increases. However, due to the large number of free surfaces of the half shaft gear, the rise of the load is relatively flat; In the third stage, the tooth cavity is basically full, the flow resistance increases rapidly, and the load increases rapidly to the maximum value.

The final forging load of half shaft gear is 14200kn. Compared with the estimated forming force, it is found that the numerical simulation forming force is between the forming force obtained from the empirical formula.

As the tooth height of the pre forging is higher than that of the forging, the top of the half shaft gear is filled first, and the filling of the gear teeth is mainly formed by upsetting. With the increase of reduction, the gear teeth are gradually filled from the top to the root. The tooth top of the half shaft gear is firstly filled to avoid the defect that the tooth top is not fully filled. At the same time, the forming load can be reduced by filling the tooth in the form of rough mark compared with filling in the form of extrusion.

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