Transactions of Materials and Heat Treatment

Title：Optimization on warm forging process for monoblock combined tooth gear based on response surface method

Authors： Wu Xianyang

Unit： Shanghai Automobile Gear Works

KeyWords： monoblock combined tooth gear warm forging process die wear response surface method finite element method

ClassificationCode：TG315.2

year,vol(issue):pagenumber：2018,43(8):27-34

Abstract：

For the defects of over load, incomplete filling of forging and terrible die wear during warm forging process of monoblock combined tooth gear, the quadratic polynomial response surface model was built for a monoblock combined tooth gear of dual clutch automatic transmission DCT250, which took the pre-heating temperature of die, heating temperature of billet, friction coefficient and forging speed as the design variables, and took the forging load,maximum wear depth of tooth profile die and forming rate of forgings as the optimization goals. Combined the response surface method with finite element method, the process parameters of warm forging process were optimized, and the optimal forging process was obtained. The optimized process was verified by the actual production. The results show that the qualified forgings can be formed under lower forming load with the optimal forging process. Also, the life of tooth profile die is improved from 1000 parts to 4500 parts, which improves the life of tooth profile die effectively.

Funds：

吴先洋（1990-），男，硕士，工程师 E-mail：xianyangw@sagw.com

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