Forming Digital Simulation and Process Research of Insufficient Filling Defects in Cold Forging in"Hot Cold Composite Forging"of Half Shaft Gear
In this paper,aiming at the full and unsatisfactory defects in the cold forging shaping in the"hot-cold compound forging"of the side gear,the cold forging blank(the workpiece formed by hot forging)is re-reformed by using software such as UG,Geomagic-Design and Deform-3D.The design and cold forging shaping process simulation simulation comprehensively examines the influence of tooth thickness and tooth height parameter changes on product quality.From the simulation results,when the cold forging shaping begins to close the mold,when the gap between the initial position of the blank and the cavity of the cold forging die is larger(the greater the increase in tooth thickness/the greater the decrease in tooth height),the final forging the greater the required forging pressure,the easier it is to form folding defects at the tooth tip of the small end of the product;the initial position of the blank is close to the tooth tip and the cavity(the increase in tooth thickness is zero or negative),it is not easy to produce folding defects.The larger the gap between the tooth side and the cavity of the cold forging die(the smaller the actual tooth thickness),the larger the required forging pressure.After actual production verification,under the conditions of the gear parameters in this paper,when the tooth height of the cold forging blank is increased by 0.1 mm compared with the cold forging die cavity profile,and the tooth thickness is unchanged,the tooth slots and tooth heights are fully pressed after cold forging shaping.The quality is good,and the product rejection rate meets the expected requirements.
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