A novel cold precision forging process of spur gear with boss and its numerical simulation

Based on the geometric feature of spur gear with boss, a new precision forging process with four measures was put forward to solve its net-shape forming problem. Took a specific gear part as an example, the rigid plastic FE model was built to simulate the precision forging process. The velocity field, stress and strain field were investigated, and the metal flow rules were discussed with the coordinate grid experimental result, also the forming force was analyzed. All the results show that the novel forging process can obtain fulfill gear forging under lower force. A general good agreement is found between the simulation and experimental results throughout the study and the novel forging process is feasible.