Analysis on Folding of Inner Flash in Synchronizer Ring
Aiming at the folding of inner flash in synchronizer ring precision forging and too big flash phenomenon, the forming process of the synchronizer ring was simulated by using Deform-3D software. The formation process and mechanism of the folding were studied. It was obtained that the main reason for the folding was unreasonable blank size so that material produced mixed flow in inner flash forming. Then the process was optimized by using FE software and the billet sizes were modified. The forming method of inner flash was translated into squeeze forming, which eliminated the folding. Finally, the synchronizer ring forgings without folding were obtained.