The Optimization of the Technological Parameters of Precision Die Forging of a Spur Gear Using a Computer Simulation

Maria Kapustova,Lubos Kravarik,Maros Martinkovic

doi:10.5539/mer.v2n1p12

Abstract

This paper deals with the optimization of the technological parameters of precision die forging in closed die in order to achieve a proper material flow in the die cavity for spur gears with a hub. This paper also studies the material flow in die cavity, effective plastic stress and strain, and temperature of drop forging using simulation software called SimufactForming. Forging cost is also compared between the closed and open die forging.

Highlights

Manufacturing processes as a product in the area of the production of drop forgings must be still analyzed and improved to meet all customers’ requirements, environmental legislation and international competition
Precision die forging can be used in a variety of dies with standard flash as well as flashless forging with open die cavity
Optimal material flow in die cavity can reached in precision hot die forging in close dies with the use of ring billet placed on the ring and container compensator placed bellow a hub

Summary

Introduction

Manufacturing processes as a product in the area of the production of drop forgings must be still analyzed and improved to meet all customers’ requirements, environmental legislation and international competition. The drop forging production using a precision die forging becomes the main field of research and development as an advanced method (Doege & Bohnsak, 2000). Precision die forging can be divided into the drop forgings produced net-shape and near net-shape (with minimal or no final-cutting operations). Precision die forging can be used in a variety of dies with standard flash as well as flashless forging with open die cavity. Application of precision die forging in forging with closed dies provides a better condition for high precision of drop forgings and utilization of forged material. Exact volume of billet (raw part) and suitable compensation method of forged material is needed to provide at the precision die forging in closed dies (Cermak, 2011; Dean, 2000)

Methods

Findings

Discussion

Conclusion