Forging process of bicycle chain wheel using experiment and finite element analysis

Various methods for bicycle chain wheel manufacture are available in the current markets. Forging is simple and inexpensive in mass production. Metallic materials are processed through plastic deformation. This not only changes the appearance but also changD e es the internal organization of materials that improve mechanical properties. The main purpose of this research was to design a forging die for bicycle chain wheels, depending on a particular company's needs. This study employed the rigid-plastic finite element (FE) DEFORM ^TM3D software to investigate the plastic deformation behavior of an aluminum alloy (A7075) workpiece as it is forged for bicycle chain wheels. Factors include the temperature of the forging billet, friction, punch speed, and mold temperature control all parameters. Moreover, this study used the Taguchi method to determine the most favorable optimization parameters, and to analyze the effective stress, effective strain, and radial load distribution of dies. Finally, the paper identified the results of simulation analyses when designing the experimental forging die to lower the deformation behavior of bicycle chain wheels.