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In the present study, billet is designed by utilizing the flow relief-hole principle to improve the dimensional accuracy during the cold precision forging of helical gear. A three-dimensional FE simulation was carried out to analyze the deformation features of billet with different initial diameter of relief-hole under the commercial software DEFORM 3D. When the diameter of relief-hole d0 increases, the forming load decreases and the unfilled portions at the teeth top contacting with the punch increase. The deform mode of relief-hole, the variation trend and the distribution of effective strain are different under different diameter of relief-hole when compression ratio Δs varies.

Three-dimensional FE simulation of cold precision forging of helical gear with the flow relief-hole method