Simulation of the precision forging of bevel gears using implicit and explicit FE techniques

The implicit FE code MARC has been used to simulate the precision forging of a bevel gear. The true coupled thermomechanical forming conditions have been adopted to describe the metal flow during the process and the results obtained have been validated by extensive experimental work. An attempt has been made also to use a time-consuming explicit FE code, DYNA 3D; however, limitations were apparent in simulating the total procedure due to structural restrictions of this code. A CAD/CAM/CAE system able to successfully analyse such a precision forging operation is on hand.