Forming analysis of closed die extrusion for spiral bevel driving gear of automotive final drive

In this paper, the metal flow route during closed die extrusion for spiral bevel driving gear of automotive final drive is analyzed and the profile of preformed blank has been designed. The metal flowing pattern of the tooth filling process at different stages during closed die extrusion is found through lead deformation test and double-acting extrusion method on a doubled-acting press or on a special die structure with a general press is proposed. Network test shows that the flow line distribution are continuous and dense, so it is considered to be the reason that forged gears have higher strength and longer life. Forged part and forming procedure and stroke-load curve obtained from rigid plastic FE simulation further discloses the deformation mechanics of closed die extrusion for spiral bevel driving gear. By comparison with experimental results, it would be proved that FE simulation is available and will provide guideline for deformation process of complex forging parts.