Modelling and Experimental Research in Hot Precision Forging of Duplicate Gear Blank

In this paper, two-steps forging is used to manufacture duplicate gear blank.The simulating of the second step forging process is based on DEFORM which is a finite element software.The forming parameter range was determined while the forging force was predicted.Using a set experiment tool of closed-die forging, teeth of forged duplicate gear blank were well filled.The influence of transition product diameter and the thickness and height of wad are researched.Too small diameter of transition product will affect the quality of the product, so the first step of forging should rigorously control the diameter of the transition product.The wad thickness has great influence on the final forging force, while the effect of the wad height is relatively small.