Study on the Precision Forging Processes of Gears using FEM Analysis

The precision forging processes for gears have advantages in saving material and energy consumption, reducing the cost and improving the quality of products. Gears have complicated geometries and are difficult in precision deformation. Two kinds of forging process of gears were put forward according to the structure characteristic of gears. 3D FEM model of the precision forging process of gears was established. The forming laws, material plastic behavior, changed geometries and the qualities of the workpieces are explored by finite element simulation. According to the simulation results, completely filled gear teeth were obtained using a lower forging load by the designed process which is the effective forging process for manufacturing of gears. From this study, it was expected that designed process could be efficiently used in the gear forging for practical use in the industry.