THE STUDY OF THE COLD FORMING CAPABILITY FOR STRAIGHT BEVEL GEARS MATERIAL AA5052 THROUGH NUMERICAL SIMULATION

Abstract

Straight bevel gears represent an effective solution for numerous industrial applications due to their prominent advantages, such as high efficiency, excellent load-bearing capacity, precise transmission, etc. This paper presents research on the precision cold forging process, utilizing finite element simulation (FEM) to form A5052 aluminum alloy straight bevel gear components using Deform-3D software. The numerical simulation provides deeper insights into deformation mechanics during cold forging through five evaluation criteria: stress distribution, strain distribution, material flow behavior during die cavity filling, forging force, and damage criterion. Furthermore, the simulation enables the prediction of altered grain flow orientation distribution within the formed component. The research results can be applied to mold design processes and equipment selection to enhance precision in the cold forging formation of various gear components.