Optical design of flashed cold die forging of car used bevel gear

Differential mechanism gear is a key part on car,finished gears whose teeth profile accuracy is high enough to be installed on car can be produced by flashed cold die forging,but the high strength and high resistance to deformation of the gear material lead to a serious stress in the die,especially the stress concentration on the die teeth tip,thus the teeth tip is very easy to collapse and rupture.In this paper,flashed cold forging die for car differential mechanism gear is studied by force analysis,finite element method and experiment during the forging procedure;Two kinds of die structure are compared,and an appropriate die structure which can efficiently prolong the life of die is obtained.