Numerical and Experimental Investigation of Cold orBital Forging of a 16MnCr5 Alloy Spur Bevel Gear

The purpose of this research is to analyze the forging of bevel gears based on conventional forging method with material number 1.7131 with finite element method by means of SUPER FORGE software and to compare it with experimental cold orbital forging results.After doing simulation of conventional forging and obtaining press tonnage due to orbital forging method with DEFORM software, orbital forging dies are produced. Since bevel gears production based on conventional forging has three pre-form steps, so the forging process should be applied on the basis of hot forge. But in orbital forging process, bevel gear is produced in only one step which is cold forge. Finally, a comparison is done between microstructure of bevel gear which is produced by orbital forging and a bevel gear that is constructed through machining method and dies. Results obtained showed that the method of pieces production just before applying the heat treatment process have a high effectiveness on the microstructure. In orbital forging the tonnage of the levels are lower than conventional forging method and the capability of filling the mold’s cavity of raw materials in orbital forging is more than conventional forging method. The geometry of the billet have more affect on filling the mold’s cavity.