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<p>This study investigates the feasibility of producing brass gears from C27000 alloy using closed-die cold forging through experimental tests and simulations, at ambient temperature. A comprehensive numerical and experimental analysis of cold forging C27000 brass gears is presented. A parametric investigation using DEFORM-3D was performed to quantify the influence of key process parameters, including tooth height, corner radius, and friction factor. The results indicate that increasing tooth height from 2.0 to 3.5&#xa0;mm reduces forming force by 6.5% (328.98-307.55 tons) due to enhanced axial material flow and a reduction in triaxial compressive stress, despite a decrease in radial flow velocity. Increasing the corner radius from 0 to 0.5&#xa0;mm facilitates material flow and yields a modest reduction in peak load by 1.0% (327.2-323.8 tons). Conversely, raising the friction factor from 0 to 0.15 increases force by 10.9% (299.8-332.57 tons) and suppresses radial flow velocity by 83%. Effective plastic strain was found to be highly non-uniform, with maximum values up to 2.7 concentrated at tooth roots, which directly correlated with experimentally measured hardness increases from 72 to 84 HV, confirming strain hardening as the dominant strengthening mechanism. Experimental validation on a 700-ton press confirmed simulation accuracy, with load–displacement discrepancy of 10% or less. A multi-criteria parametric screening approach was employed to define a practical process window rather than a formal optimization framework. An optimal parameter combination (tooth height = 3.2 mm, corner radius = 0.4 mm, friction factor = 0.08) reduced the forming force by 8.2% and improved die cavity fill uniformity from 91 to 94%, enabling operation at approximately 86% of press capacity.</p> Graphical Abstract <p></p>

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Numerical and Experimental Analysis of Brass Gear Manufacturing Using Cold Forging

  • 期刊论文

  • 发表日期：

    2026年5月23日

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  • Elyas Haddadi,
  • Hossein Jafarzadeh

摘要

This study investigates the feasibility of producing brass gears from C27000 alloy using closed-die cold forging through experimental tests and simulations, at ambient temperature. A comprehensive numerical and experimental analysis of cold forging C27000 brass gears is presented. A parametric investigation using DEFORM-3D was performed to quantify the influence of key process parameters, including tooth height, corner radius, and friction factor. The results indicate that increasing tooth height from 2.0 to 3.5 mm reduces forming force by 6.5% (328.98-307.55 tons) due to enhanced axial material flow and a reduction in triaxial compressive stress, despite a decrease in radial flow velocity. Increasing the corner radius from 0 to 0.5 mm facilitates material flow and yields a modest reduction in peak load by 1.0% (327.2-323.8 tons). Conversely, raising the friction factor from 0 to 0.15 increases force by 10.9% (299.8-332.57 tons) and suppresses radial flow velocity by 83%. Effective plastic strain was found to be highly non-uniform, with maximum values up to 2.7 concentrated at tooth roots, which directly correlated with experimentally measured hardness increases from 72 to 84 HV, confirming strain hardening as the dominant strengthening mechanism. Experimental validation on a 700-ton press confirmed simulation accuracy, with load–displacement discrepancy of 10% or less. A multi-criteria parametric screening approach was employed to define a practical process window rather than a formal optimization framework. An optimal parameter combination (tooth height = 3.2 mm, corner radius = 0.4 mm, friction factor = 0.08) reduced the forming force by 8.2% and improved die cavity fill uniformity from 91 to 94%, enabling operation at approximately 86% of press capacity.

Graphical Abstract