THE SIMULATED DESIGN OF DIE FORGING TECHNOLOGY OF PRECESSIONAL BEVEL GEAR BY SEVERE COLD PLASTIC DEFORMATION

Alexandru MAZURU, Alexei TOCA, Sergiu MAZURU, Tudor CHERECHEŞ

Abstract


Simulation of closed die forging processes is a powerful tool for technological design-optimization that provides details regarding the shape evolution, plastical flow, required forging forces, stress and deformation states, allowing like this the exclusion of costly real repeated tests. In this paper, the LS-DYNA simulation tool is used to design the precessional bevel gear's  forging technology in closed die, following preliminary simulations on partial models reduced to one tooth, respectively to one gap, simulations on models reduced to 1/4 of the wheel and on the integrated model.It is found that it is preferable to form the wheel with a bore in the hub, because this ensures a better balance between the masses of material located in different areas of the die forged bevel gear starting from a blank in the form of a  disc. The formation of the bore in the hub requires plastic deformation actions located both in the teeth area and in the hub area, making it necessary to include in the closed  die's structure a mandrel with an action separate from the punch, but synchronized with its action.

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References


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