Combined with the numerical simulation analysis results and the best process parameters, experimental research is carried out to verify the accuracy of the simulation results. The test mainly includes the following three parts:
Part I: comparison of helical gear process schemes. Take the preforms with the same shape and blank volume, and compare the maximum forming force required by the double split forming scheme and the inner split forming scheme.
Part II: the comparison of the position of helical gear split surface. The preforms with the same shape and blank volume were selected for the test. The inner shunting surface was fixed (away from the tooth shape of the die). By adjusting the position of the outer shunting surface, the influence of different positions of the outer shunting surface on the filling fullness of the tooth shape was studied.
Part III: comparison of preform cone angle. The preforms with the same volume but different shapes are selected and tested by changing the cone angle to observe the filling fullness of each part of the tooth shape at the end of forming.
Since the helical gear of the automobile rear axle is the key part to transmit power, the gear module is large, and the diameter of the part reaches 167.5mm. In the process of numerical simulation, the hot forging method is used to form the helical gear, which requires a forming force of about 7200kn to ensure the full filling of the tooth shape. Due to the limited test conditions, lead was selected as the preform to replace 20crmoti in the numerical simulation, and the modulus of helical gear was changed from 3.7 to 1.5. The forging forming test was carried out on 300KN universal material testing machine, which was compared with the numerical simulation results to verify the accuracy of the numerical simulation results.