An investigation on deformation mechanism of non-standard gear teeth forming in the hot impression forging of multicore cable cutter

On this study, a hot forging process in making non-standard gear will be experimentally as well as numerically researched and verified by simulation. The purpose of the research is to look for the crucial station of the finishing forging process and also to realize the particular non-standard gear teeth forming within the closed die hot impression forging associated with multicore cable cutter and replace the traditionally investment casting and open die forging counterparts. Furthermore, in order to make certain realize the non-standard gear teeth forming, the novel extrusion-forging teeth forming (EFT) approach is proposed and simulated from the commercially obtainable finite element software Qform 3D, the procedure parameters on the non-standard gear teeth forming are methodically analyzed and also carefully in contrast to experimental research. Based on consequents of the simulations, the distributions associated with forming, stress, strain, and temperature have been obtained to describe the microscopic phenomena. Accuracy from the numerical models have been verified by comparing with experimental dimensions. The proposed modified geometry from the forged preform has been finally proposed to to attain a similar forming situation while decreasing manufacturing expenses. The the extrusion-forging ratio ([Formula presented]) and the fractional reduction in area ([Formula presented]) of the proposed EFT method can be calculated as R₂ = 1.38 and r₂ = 0.28 respectively for the modified geometry of preform 2. We expect that this advancement can provide a valuable and useful technical reference for the forging customized gears associated with any geometry.