Research on Material Flow Behavior of Gear Blank with Deep Spoke During Multi Station Close Die Forging

Exploring the material flow behavior during the closed die forging is the theoretical basis for controlling forming defects such as insufficient filling and obtaining high-precision die forgings. In response to the problem of insufficient filling during hot die forging of gear blanks with deep spoke, this study selected the SCr420H gear blank with deep spoke as the research object and designed a multi-station closed hot die forging process of“cutting—heating—upsetting—preforging Ⅰ—preforging Ⅱ—final forging”based on structure analysis of the gear blank. Based on Deform, it established a finite element simulation model for the entire process of multi-station closed hot die forging. The reliability of the finite element model was verified by the experimental results, and the material flow law during the multistation closed hot die forging process was studied. The results show that a circular cake shaped blank can be obtained when the upsetting ratio is 3.7. The material flow along radial direction is uneven due to the friction effect between the upper and lower surfaces, resulting in a bulge shape at the waist of the billet during upsetting. A concave structure was formed on the bottom surface for positioning during pre-forging station Ⅰ, and it reduced the difficulty of material filling in subsequent stations. The material flow law during pre-forging Ⅱ and final forging are similar. The material mainly flows to the wheel flange part in the early stage of forming. It mainly flows to the wheel hub part in the middle stage, and flows to the rounded corner in the late stage. There is no defect of insufficient material filling during final forging. In the late forming stage, a small amount of metal material flows out of the guide gap of the upper and lower die of the final forging, forming a longitudinal flying edge. Through the production test, the well-filled gear blank with deep spoke was formed. The maximum error between the simulated value and the actual production value is not more than 3.15%, the longitudinal flying edge height is less than 0.5 mm, and the size deviation of each part is less than 0.2 mm, which verifies the rationality of the designed multi-stage closed die forging process.