Practical Study and Finite Element Simulation of Production Process of the Bush of Gearbox of Mercedes-Benz 10-Wheel Truck by Closed Die Forging

Nowadays, the closed die forging process is extensively applied to produce small to medium parts. The parts produced by this method show high strength, impact resistance, and toughness, which is the main advantage of this method compared to casting. Furthermore, the parts produced by this method are considerably close to the final shape of the designed part in terms of appearance compared to the open-die forging process, and the need for secondary operations such as finishing after the subjected process is significantly reduced. The present work investigates the production process with closed die forging of one of the most important parts of the gearbox of Mercedes-Benz 10-wheel truck, which is affected by various mechanical and thermal stresses in its working conditions. Finite element simulation results in ABAQUS software have been applied to analyze experiments for the purpose of evaluating the extent and type of impact of some important process parameters and also compared with the observed practical results. The results indicated that the initial temperature parameter of the workpiece has the highest effect on reducing the flow stress, and consequently, the required maximum force throughout the process. While the other evaluated parameters, i.e., press speed and mold temperature, have a smaller but undeniable impact.