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In extruding the dual clutch hub with small fillet gear, the filling of small fillet gear is not complete due to the large forming resistance. A method of preforming the blank into a concave shape is proposed. The mechanical analysis and finite element simulation are used to analyze the principle that the blank of concave shape can promote the filling of small fillet gear, stamping and extruding are both used to form the dual clutch hub and the preform is used to simulate the fillet gear’s extruding to analyze the influence of the geometric parameters of the preform on the forming quality. The mapping relationship between the geometric parameters of the preform and the size of unfilled fillet gear is established by using the BP neural network. The multi-objective genetic algorithm is used to optimize the geometric parameters of the preform. From the results we can see that the frictional resistance decreases due to reduced contact area between the blank and the mold when the section shape of the blank is concave, and at the same time, the tangential thrust is generated on the blank, so the filling of small fillet gear is better; BP neural network combined with genetic algorithm can reliably optimize the geometric parameters of the preform. The filling performance of the fillet gear is better under the optimal preform, and the forming quality of the dual clutch hub is improved. The experimental result verified the feasibility of the method and the accuracy of the simulation.

Exploring Filling Law of Small Fillet of Dual Clutch Hub