Experimental and FE analysis to predict the dimensional changes of workpiece and tool in cold forging

Abstract

The dimensional tolerance of spur gear for automobile would be within the range of a several micrometer. Therefore, to manufacture these gears by cold forging, dimensions should be controlled in same range. The dimensional changes by the various forging variables should be analyzed and compensated into the forging tool. CAE would be appropriate for investigating the effects of variables. However, the realistic FE‐modeling techniques should be confirmed and used to predict the dimension of forged part in micrometer order. Since the realistic modeling considers elastic characteristics of both workpiece and die and unloading and ejecting stage, 3‐dimensional analysis for spur gear may be often facing difficulties in a solving time and convergence. In this study, dimensional changes for cold forged part of spur gear were investigated by experimental and FEM analysis, after FE modeling to get the desirable FEM results had been studied by the closed die upsetting. The dimensional changes of involute curve for s...