Transactions of Materials and Heat Treatment

Title：Improvement of service life for gear blank forging die based on FEA

Authors： Zhang Hao Guo Lei

Unit： Zhongshan Technical Institute University of Electronic Science and Technology of China

KeyWords： closed forging die cracking die wear die life forging times

ClassificationCode：TG315.2

year,vol(issue):pagenumber：2022,47(10):250-256

Abstract：

In order to save consumables, reduce processes and improve accuracy and performance of product, the manufacturing method of gear blank is gradually changing from open forging to closed forging, but the closed forging usually requires greater forming force, which is easy to cause die cracking and aggravate die wear. Therefore, aiming at this problem, two kinds of closed forging structures of gear was increased were analyzed, and the appropriate forging die structure was determined to solve the problem of die cracking and the die life from 2600 pieces to 4120 pieces. On this basis, using the method of combining finite element analysis (FEA) and orthogonal test, the influences of different combinations of blank heating temperature, die preheating temperature, upper die bottom angle and upper die fillet on the single wear depth of the upper die were obtained, and with the ultimate goal of reducing the single wear of the upper die, the optimal level of each parameter was determined by the range analysis method. Then, the optimal parameters were used to simulate twenty-four times of forging in the form of cumulative wear, the functional model of the total wear depth of the upper die and the number of forging was obtained by fitting, and the service life of the upper die was inferred. Thus, after the process parameters were improved, the service life of die was increased from 4120 pieces to 7860 pieces.

Funds：

张浩（1985-），男，硕士，高级讲师，E-mail：zhanghao198508@163.com；通信作者：郭磊（1978-），男，博士，教授，E-mail：13824760975@139.com

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