With the development of auto manufacturing technology, the forging process technology of synchronous ring, as an im portant component of automobile manual transmission, is also being received attention. Forging mechanism is very complicated, and numerical simulation is the most effective method for analyzing the plastic formation process at present. The forging process of the new synchronizer ring of heavy-duty truck was introduced, and the application of precision forming process in production was described. The process of forging was simulated by means of finite element numerical simulation, and the forging behavior of the stuff during process of forging test was simulated. Meanwhile the faults possibly occurred during the forming like folding and crack were predicted. The results indicate that the simulation results are in conformity with engineering practice. On the base that synchronizer ring are well formed under optimized parameter, material utilization ratio is improved and cost of the products is reduced.%随着汽车制造技术的发展,作为汽车手动变速器关键零部件之一的同步环的锻造工艺也受到重视.锻造成形机理非常复杂,数值模拟是目前塑性成形分析中最有效的方法.介绍重型汽车新型同步环的锻造工艺,阐述精密成形工艺在生产中的运用,并对锻造成形过程进行了有限元数值模拟,模拟锻造成形过程中坯料的变形行为,同时对成形过程中的缺陷如折叠、裂纹进行预测.结果表明:模拟结果与实际生产相符.利用优化的参数来保证同步环的成形质量,可以有效地提高材料利用率,降低产品生产成本.
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