Hot forging process design of sprocket wheel and environmental effect analysis

Manufacturing industries have become increasingly conscious of energy wastage and environmental emissions. The energy consumption and environmental effect of each manufacturing process is different. This study aims to compare the environmental effects of the hot forging process and machining process for manufacturing sprocket wheels. It is important to design a preform when forging a sprocket wheel. The sprocket wheel tooth section is the weak point in folding, and an unfilling defect may occur. Therefore, preform and flash stopper shapes are critical design factors in the hot forging process for manufacturing sprocket wheels. Finite element analysis was used to design the preform, and analyze the deformation and effect of flash stopper in the hot forging process. The energy consumption for an actual product and for a product based on the analysis were compared to analyze the environmental effects. The results showed that the material loss and energy consumption were reduced in the developed hot forging process; this process is a green process with comparatively higher energy saving than the machining process.