3D FEM simulation of flow velocity field for 5052 aluminum alloy multi-row sprocket in cold semi-precision forging process

Based on the design of the multi-row sprocket with a new tooth profile, a cold semi-precision forging process for manufacturing 5052 aluminum alloy multi-row sprocket was presented. Through simulating the forging process of 5052 aluminum alloy sprocket billet with 3D rigid-viscoplastic FEM, both the distributions of flow velocity field in axial (UZ), radial (UR) and circumferential (Uθ) directions and the curves of velocity component in different deformation regions were respectively obtained. By comparison and analysis of the velocity varying curves, the velocity component relation conditions for filling the die cavity were clarified. It shows that when the die cavity is almost fully filled, the circumferential velocity Uθ increases sharply, implying that Uθ plays a key role in fully filling the die cavity.