Aiming at the problem of low utilization rate and large forming load for the hot precision forging of the copper synchronizer ring

the hot precision forging process was analyzed by the finite element software FORGE.Based on the metal plastic forming theory

the metal flow law was analyzed during synchronizer ring forming.Four factors and four levels orthogonal experiment was performed to obtain the data of maximum forming load and radial dimension of inner and outer flash with billet temperature

friction factor

inner diameter and height of billet as design variables.The grey system theory was adopted in the parameters optimization of hot precision forging of synchronizer ring

and the optimized combination of process parameters were presented for the production.The results reveal that the synchronizer ring is filled with fullness and absence of folding defect and crack.Meanwhile

the material utilization rate is improved from 44.67% to 63.73%.The feasibility of the forming process and the grey system theory was verified sucessfully.