Abstract
Abstract
Among all manufacturing processes, a forging process has a remarkable position in which parts with desired mechanical properties and minimum wastage of material can be produced. Despite of mentioned advantages, forging process has few drawbacks such as high tonnage capacity machineries, expensive dies, high initial investment and die failure. The overall cost of the forging process directly depends upon the required forging load, ejection load and dies arrangements. In this paper, Finite Element Analysis (FEA) of a spur gear forging process made of low carbon alloy steel (AISI 8620) is carried out. Two load reduction methods (elastically attached die and relief hole) are simultaneously used and analyzed using DEFORM- 3D software. The required forging load is compared between non-elastic die arrangements and elastic die arrangements with the relief hole. Velocity distribution is also discussed at nine different locations.