Analysis of Metal Flow and Technology Improvement on Synchronizer Ring Precision Die-forging

The metal flow ruler in synchronizer ring forging process was analyzed.In order to eliminate the split on the top of gear next to spline during forging process,the radial extrusion was replaced by the method of upsetting and extruding to optimize metallic flow actions.The forging process was simulated by rigid-plastic finite element model combining with FEM software.The results show that the major factor causing split is difficult filling on the top of tooth.The metallic radial and axial flow actions of ring tooth forging are optimized by extending inside and external diameter of blank and modifying the blank positioning mode.The results show that the new process achieves synchronizer ring with full teeth.The split doesn't appear in the tooth top of quantity production rings.