Abstract: This article conducts ultrasonic assisted extrusion research on the forming process of automotive starting gears based on DEFORM-3D software. Using conventional extrusion (without ultrasonic vibration assistance) as a control experiment, a finite element model is established to analyze the changes in load, stress field, strain field, and forming temperature during the extrusion forming process. The control test results showed that under the action of ultrasound assisted vibration, the peak load decreased by 4.7% and the average load decreased by 7.5%; The maximum equivalent stress decreased by 9.13%, and the average equivalent stress decreased by 9.8%; Reducing the working stress and load of the mold has potential significance for extending its service life. The equivalent strain and forming temperature increased by 9.3% and 5% respectively. The increase in billet temperature is beneficial for improving plasticity and reducing internal stress. The increase in equivalent strain indicates that the material deforms more fully and has better fluidity, which is conducive to filling the mold cavity. Ultrasound assisted extrusion, compared to conventional extrusion, can effectively reduce forming stress, increase material fluidity, and is of great significance for improving the mechanical properties of formed parts.
Key words: Starting gear; ultrasonic extrusion; stress; strain