Numerical Investigations on the Influence of Process Parameters on the Forming of Gears in Forward Extrusion

The manufacturing of steel gears by cold forging can be realized by using the so called Samanta process. The present study focuses on the one hand on the FE based analysis of the forming of gears in forward extrusion and on the other hand on the modelling of a Samanta process, using the software Simufact.forming. Thereby the influence of different tool geometries and the tribological conditions on the forming are investigated. The aim is to obtain a basic understanding of the material flow and the filling of the tooth cavity depending on the geometry of the Samanta process. For the investigations the common heat-treatable steel 1.7131 (16MnCr5) was used. As an input parameter for the simulation the true stress-true strain curve of the material has been determined within compression tests. For the analysis of the forming the material flow into the cavities and the shape of the tooth flanks are evaluation criteria. Thus the influence of the different parameters on the distribution of equivalent plastic strain, the forming and the reachable accuracy have been investigated.