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Theoretical Analysis and Numerical Simulation of Ejection Demolding Process Parameters for Large Cylindrical Helical
Aihua Zhang1, Guosheng Fei1, Xiaoci Chen1
1Sichuan Provincial Engineering Research Center of Aeronautical Material Testing and Die Forging Technology, College of Materials Engineering, Sichuan Polytechnic University, Deyang 618000, China.
Materials (Basel, Switzerland)
|May 27, 2026
Summary
Optimizing die forging of large helical gears requires controlling friction and ejection velocity. Lowering these parameters reduces ejection load, strain, and damage, ensuring better gear quality.
Area of Science:
- Manufacturing Engineering
- Materials Science
- Tribology
Background:
- Die forging of large cylindrical helical gears presents challenges with difficult demolding.
- High ejection loads, effective strain, and damage can compromise gear quality.
Purpose of the Study:
- To investigate the demolding technique for large cylindrical helical gears after die forging.
- To analyze the influence of friction coefficient and ejection velocity on the demolding process.
Main Methods:
- Establishment of a mechanical theoretical model for forging ejection and demolding.
- Quantitative analysis of friction coefficient and ejection velocity effects on ejection load, strain, and damage.
Main Results:
- Increased friction coefficient significantly elevates ejection load, effective strain, and damage.
- Higher ejection velocity also leads to sharp increases in ejection load, effective strain, and damage.
Conclusions:
- Optimizing friction coefficient (0.25-0.30) and using low ejection velocity are crucial for successful demolding.
- These optimized parameters reduce ejection load, strain, and damage, ensuring stable forging quality for large helical gears.
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