Research on process and simulation of the isothermal forging of a spur bevel gear

Abstract

This paper took the lead in applying isothermal forging technology to form a spur bevel gear in a single operation. According to the isothermal forging process, the forging part drawing of the spur bevel gear was defined. The 20CrMnTi was chosen as the gear materials. A closed-die structure was used in the forging process. Then, the model of the dies and workpiece were built by UG software. After the models was imported into DEFORM-3D, the simulation of the isothermal forging process of the bevel gear was executed. Through simulation, the shape of the gear, the distributions of effective stress and strain, the forming load of the dies, the laws of metal flow and the filling of the metal during the forging process were gained and thoroughly discussed. The results revealed that the full forging process can be divided into four periods and precision spur bevel gear can be obtained without causing under-filling and folding defect by using the isothermal forging with closed-die forging structure, which provides guidance to manufacturing the spur bevel gear.