J. J. Sheu, C. H. Yu (2007) The Cold Orbital Forging Die and Process Design of a Hollow-ring Gear Part, Proceedings of the 35th International MATADOR Conference 2007, pp 111-114.
------------------------------Abstract
In this paper, the cold orbital forging die is designed to make a hollow ring gear part. The forging process with suitable preform design is proposed to obtain the sound cold orbital forging gear part. Different preform designs have been studied to find out the deformation characteristic of the orbital forging process. The dimensions of height and outer diameter of a preform design are considered as the main design parameters. The 3D FEM simulation has been adopted to evaluate the process and die design, and predict the forging loads. The Cockroft-Latham damage criterion has been adopted to evaluate the quality of the product. The upsetting tests of workpiece SCM415 have been carried out to obtain the flow stress model. A PXW-200 orbital forging press has been adopted to do the experimental tests. The top die is rotating in the orbital motion way, and the bottom die only has translational motion. The circular locus is chosen to guarantee the gear shape can be forged precisely. The conventional closed die forging results have been compared with the orbital forging. The forging load of conventional forging is about three times of the orbital forging. The orbital locus shows a better ability of die filling at the finishing than the conventional forging. The simulation results are in good agreement with the experimental tests. The von Mises stress, effective strain, and damage value of the workpiece have been studied to develop a better forging die and process design.
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