Taking the forging compound forming process of driving and driven spiral bevel gears as the research object, the feasibility of the compound forming process is verified by numerical simulation. A very professional finite element numerical simulation software in the field of metal plastic forming is selected to simulate the process of cross wedge rolling and die forging in the compound forming process. The simulation results and conclusions are as follows
(1) The optimum blanking diameter is Ф 70mm, when the bar diameter is Ф 70mm, it can not only meet the reduction of section of secondary wedging in cross wedge rolling, but also avoid the defects of looseness or helix; It can also meet the upsetting ratio and avoid upsetting folding instability and other defects.
(2) When the upsetting reduction is Δ 95mm、 Δ 100mm、 Δ The results show that the best upsetting pressure is. When the lower pressure is too small, the upsetting cake is thick and the upsetting diameter is small, so it is difficult to fill the rim during pre forging. When the lower pressure is too large, the diameter of upsetting cake is too large and the thickness is small, so it is difficult to fill the hub during pre forging.
(3) Through the comparative analysis of the new and old processes, it is concluded that the composite forming process has the advantages of material saving, energy saving and low consumption compared with the existing forging process, and can improve the utilization rate of materials.
(4) The compound forming process combines the two production lines into one, eliminating the repeated processes, such as feeding, heating, and skillfully integrating the closed die vertical forging into the pre forging step, using less equipment to realize blanking, heating, cross wedge rolling, upsetting, pre forging, final forging, master-slave separation and seven steps of production. Through the comparative analysis of the new and old processes, the compound forming process can further improve the production efficiency because of less steps and saving a lot of time.
(5) The numerical simulation shows that the composite forming process of driving and driven spiral bevel gear blank of automobile rear axle can obtain qualified forgings.