Transactions of Materials and Heat Treatment

Title：Spur/helical gear precision forming by expanding die cavity at bottom corner

Authors： Zhang Ruhua Long Qibo Wang Lei Yin Yan Huang Zhisong Chen Jia

Unit： Nanchang University

KeyWords： no-flash die forging spur/helical gear expanding die cavity divided flow forming push sizing

ClassificationCode：TG316

year,vol(issue):pagenumber：2016,41(9):23-27

Abstract：

In order to realize the spur/helical gear precision forming by one step and overcome a series

of deficiencies such as less full tooth corner, big forming force, complex mold structure,

complex motion requirements of equipment in the current process, a new forming technology of

no-flash die forging was put forward. The forming process was divided into upsetting and

ejection stages, and applied in the expanding die cavity at die bottom corner. For the entity

spur gear with modulus 4, teeth numbers 12 and teeth width 30 mm, the process of metal filling

at two stages and the comparison with conventional no-flash die forging were observed and

analyzed by flow net function of the Deform software, which used the expanding die cavity with

optimized geometrical parameters from two weft surfaces reflecting the fill effects of top and

bottom corners the best from the exterior and interior. The result shows that when upsetting

is over, the top corner fills well, while the bottom corner is not full and the proper volume

flows into the expanding cavity. Therefore, compared with conventional no-flash die forging,

the upsetting force obviously drops. At the ejection stage, under the influence of slanted

side, the volume that previously flowing into the expanding cavity flows back to the bottom

corner, and the bottom corner is filled. New technology combines the advantages of divided

flow forming and push sizing, and simplifies the mould structure and motion requirements of

the equipment. Furthermore, the effect of new technology is verified by physical experiment.

Funds：

江西省发明专利研发引导项目（20143BBM26105）；江西省教育厅科技计划项目（GJJ13192）

张如华（1958-），男，硕士，教授

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