Parametric Analysis and Optimization of Closed Die Forging of Gear Blank

Objectives: To analyze the effect of change of input parameters on the forging process using industrial component, a gear blank using the technique of FEM. Methods/Statistical analysis: The input parameters of billet shape/size, forging temperature and coefficient of friction between die workpiece interfaces were selected and the simulated experiments were designed using the technique of Response Surface Method (RSM). The simulations were done using Simufact®(MSC Corporation). The results were analyzed on die filling, defects and flash reduction. Findings: The deformation process was observed by defining flow lines and flow particles in the workpiece. The quantitative data from the flow particles gave the standard deviations of all the responses i.e. shear and normal stresses, effective plastic strain, effective stress, effective strain rate, material flow rate, load and die wear. These values were analyzed by using ANOVA and the significant parameters were highlighted. It was concluded that the parameters in the decreasing order of significance were billet size, coefficient of friction and temperature of billet. The graphical results were checked for defects, die filling and flash. Based on the simulated analysis and experimental values, mathematical models have been developed for die wear, effective strain rate and material flow rate with error ranging from 4% to 9%. It was concluded that for a defect free forging, a homogenous deformation and proper material flow with increased die life were important. Application/Improvements: The experimental production runs have shown remarkable improvement in reduction of rejects. The flash has been reduced by 60%, resulting in the saving of material.