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Abstract <p>This study investigates the hot forging of a straight bevel gear shaft made from DIN 15CrNi6 steel under realistic hydraulic press conditions using DEFORM-3D simulations. A Box–Behnken design with three variables—billet temperature (1000–1200°C), punch velocity (10–60 mm/s), and friction coefficient (0.1–0.5) was used to assess their effects on forging force and billet temperature. Regression models showed billet temperature and friction were key factors for forming load, while punch velocity strongly influenced thermal retention. A multi-objective optimization using the NSGA-II algorithm yielded an optimal configuration: 1200°C, 43.8 mm/s, and 0.10, achieving a reduced maximum forging load of 106.5 tons and a heat loss ratio (HLR) of 32.5%. The results demonstrate the benefit of integrating finite element modeling with evolutionary optimization to enhance the process design for complex gear forging applications.</p>

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Simulation-Based Optimization of Bevel Gear Hot Forging Using Box–Behnken Design and Genetic Algorithm

  • 期刊论文

  • 发表日期：

    2025年7月1日

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  • Ta Dinh Xuan,
  • To Thanh Loan,
  • Tran Duc Hoan

摘要

Abstract

This study investigates the hot forging of a straight bevel gear shaft made from DIN 15CrNi6 steel under realistic hydraulic press conditions using DEFORM-3D simulations. A Box–Behnken design with three variables—billet temperature (1000–1200°C), punch velocity (10–60 mm/s), and friction coefficient (0.1–0.5) was used to assess their effects on forging force and billet temperature. Regression models showed billet temperature and friction were key factors for forming load, while punch velocity strongly influenced thermal retention. A multi-objective optimization using the NSGA-II algorithm yielded an optimal configuration: 1200°C, 43.8 mm/s, and 0.10, achieving a reduced maximum forging load of 106.5 tons and a heat loss ratio (HLR) of 32.5%. The results demonstrate the benefit of integrating finite element modeling with evolutionary optimization to enhance the process design for complex gear forging applications.