Simulation and analysis of gear cold extrusion forming process

Simulation and analysis of gear cold extrusion forming process

China roll forming machine Supplier shared that gear is a widely used mechanical transmission parts, cold extrusion is one of the manufacturing methods of gear. The influencing factors of gear cold extrusion process were analyzed by numerical simulation. It was found that the blank selection should take into account the size of the impact pressure and the shape of the parts, preferably the same as or 1~2mm larger than the top circle of the tooth. The perforated extrusion in the blank can reduce the extrusion pressure by about 10%, thus reducing the force on the die, reducing the wear of the die and improving the service life of the die. Punch with boss, boss height should be less than the punch Angle height, otherwise it will lead to internal cavity. The die entry Angle should be enlarged as far as possible to reduce the force. The mandrel in die has a great influence on the force of punch, which increases with the increase of diameter. Composite extrusion is a good gear forming method, which can reduce material consumption and subsequent cutting.

Gear is widely used mechanical transmission parts, gear complex shape, processing and high performance requirements. The traditional method of gear processing is mechanical processing, generally using gear shaping or gear hobbing method, which requires professional processing equipment, slow processing speed and low efficiency. Cold extrusion technology processing gear, can overcome many shortcomings of mechanical processing, processing speed is fast, generally a few seconds to complete a part extrusion, especially suitable for mass production, in mechanical parts, especially automotive parts have been widely used.

In the process of cold extrusion, there are many influencing factors, such as extrusion pressure, materials, molds, equipment, etc., among which extrusion pressure is a major indicator. The extrusion pressure directly affects the die force and die life, which is a very important problem in the design. The die structure and shape can be optimized by means of extrusion analysis. Conventional analysis of extrusion pressure is based on some empirical formulas, but it is difficult to calculate accurately for some complex structures. With the development of computer technology and finite element theory, numerical simulation technology has been widely used in the process of forming simulation.

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