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Flange gear has a complex geometry and its volume distribution along the axial direction changes suddenly. This makes it difficult to be formed by a single step using a simple cylinder workpiece and the preform is necessary. This research aims at proposing a preform designing approach in cold orbital forging of flange gear. A three-dimensional finite element model of cold orbital forging of flange gear is first constructed. Then, the cold orbital forging processes are simulated under different preform geometries and the insufficient filling and folding defects are studied. At last, the preform is optimized and the defects are eliminated. The experiments are also performed and the preform designing approach in cold orbital forging of flange gear is verified.

Preform designing approach in cold orbital forging of flange gear