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<p>This study presents an experimental and numerical investigation of the closed-die forging of C85700 leaded yellow brass spur gears. Three-dimensional finite element simulations using DEFORM-3D were conducted to analyze the influence of forging temperature between 400 and 700&#xa0;°C on strain, stress distribution, and die filling. Experimental validation was performed using a 700-ton hydraulic press under the same conditions. The results indicated that the maximum equivalent plastic strain was located at the tooth root, whereas the minimum was observed at the gear core. Increasing the billet temperature from 400 to 700&#xa0;°C reduced the forging load from about 250 to 100 kN and the effective stress from 250 to 80&#xa0;MPa, mainly due to dynamic recrystallization. Microstructural analyses confirmed a dual-phase<i> α</i> and <i>β</i> structure at all temperatures, changing from fine lamellar at 500&#xa0;°C to coarse equiaxed at higher temperatures. The highest Vickers hardness of 178 HV was obtained at 500&#xa0;°C, corresponding to a fine lamellar microstructure and accurate die filling of about 95%. Based on the combined experimental and simulation results, the optimal forging temperature for C85700 brass gears is 500&#xa0;°C, which provides high hardness, sufficient formability, and low forming load, improving gear quality and die life.</p> Graphical Abstract <p></p>

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Experimental and Numerical Investigation of Closed-Die Forging of C85700 Brass Spur Gears

  • 期刊论文

  • 发表日期：

    2026年5月23日

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  • Hossein Jafarzadeh,
  • Elyas Haddadi

摘要

This study presents an experimental and numerical investigation of the closed-die forging of C85700 leaded yellow brass spur gears. Three-dimensional finite element simulations using DEFORM-3D were conducted to analyze the influence of forging temperature between 400 and 700 °C on strain, stress distribution, and die filling. Experimental validation was performed using a 700-ton hydraulic press under the same conditions. The results indicated that the maximum equivalent plastic strain was located at the tooth root, whereas the minimum was observed at the gear core. Increasing the billet temperature from 400 to 700 °C reduced the forging load from about 250 to 100 kN and the effective stress from 250 to 80 MPa, mainly due to dynamic recrystallization. Microstructural analyses confirmed a dual-phase α and β structure at all temperatures, changing from fine lamellar at 500 °C to coarse equiaxed at higher temperatures. The highest Vickers hardness of 178 HV was obtained at 500 °C, corresponding to a fine lamellar microstructure and accurate die filling of about 95%. Based on the combined experimental and simulation results, the optimal forging temperature for C85700 brass gears is 500 °C, which provides high hardness, sufficient formability, and low forming load, improving gear quality and die life.

Graphical Abstract