In this paper, an electromagnetic shell part was studied with the design of die, simulation and the flow control forming (FCF) method. The important technology of FCF was the design of cavity die to control metal flow. The simulation results indicate that pyramidal faces of cavity die exerted a significant influence on qualities of parts. The simulation results also revealed that the effective stresses of the sheet were inhomogeneous and the distributions of the equivalent stress were lamellar with obvious gradients. Experimental results show that steel sheet (08Al) could be formed in one step into intricate shapes at room temperature. This confirmed that FCF is a safe, clean and practical method for the near net forming of parts.

Taking the Planetary Bevel Gears as an object, the characteristic of cold Closed-die Forging was studied. By Using the FEM, the flowing rule of metal in the process of cold forging were analyzed, which is composed of dual-direction extrusion, upsetting and filling the gear form. The results show that each district of cavity was filled completely at the end of forging, without corner collapse, fold or crack. Taken the lower die as an example, the distribution of die stress was also analyzed. The results of numerical simulation were proved by the experiments, meanwhile the high precision and quality forging was formed. To the gears, the cold closed-die forging can not only ensure the dimensional precision, but also improve the capability of the gear, while obviously reduce materials consumption.