An example of tool optimization for gear wheel forging is shown below.
The initial technology consisted of two operations and a one-piece top die was used for the second operation. In this example the top die suffered from short die life and the die failed after only 400 forged parts.
In the simulation results below you can see the high strain and effective strain that cause the short die life. QForm also allows the user to add their own user defined functions (UDF) to investigate problems such as this. In this example the danger zone in the tool has been confirming of by means of Cockcroft & Latham criteria.
The extensive experience of our specialists in the metal forming industry has helped to solve this problem by using an assembled tool rather than a solid tool and simulation in QForm software has confirmed that this significantly improves the tool life. The Cockcroft & Latham simulation results show that the modified design of the tools increased the tool life by three times.
Gear wheel forging in two operations is shown in the video. An assembled tool was used for final forming. Effective stress field is shown for the first operation, plastic strain – for the second operation.