The whole production process of driven spiral bevel gear blank is simulated, and the ring rolling steps are mainly introduced. At the same time, aiming at the wear failure and fatigue failure of closed die forging die, the influence of forming process parameters and die cavity geometry parameters is analyzed, which provides a new method and way for the design and optimization of driven spiral bevel gear blank preform and die. It is summarized as follows:
(1) The whole manufacturing process of driven spiral bevel gear blank is simulated by elastic-plastic finite element model. The simulation results show that the forming quality is good, which shows that the finite element method is effective to analyze the shape change of blank and the mechanical behavior of die in the forming process. This provides a reference for the preform shape design and die design in the production process of similar plastic workpieces.
(2) Ring rolling is an important step in the production process of driven spiral bevel gear blank. In modern society, the impact of production activities on the environment has become increasingly important. In the process of obtaining the required parts, it is also very important to reduce the ability of material scrap and useless material heating. The correct definition of the geometry of Middleware (preform) is the basic task to achieve two objectives. Based on this assumption, this paper considers different preform geometries (characterized by different initial Heights) to simulate the ring rolling process, and pays attention to the ring quality obtained by ring rolling (which affects the number of scrapped workpieces) and the required energy and force (which affects the selection of equipment).
(3) The modified Archard model is embedded into DEFORM-3D to realize the die wear analysis in the hot forging process of driven spiral bevel gear blank. The influence law of various parameters on die wear and forming load is obtained by using the orthogonal analysis method. Then the simulation results are optimized by using the comprehensive balance method, and the verification test is carried out. The experimental results are consistent with the reality. This provides effective basic data for the optimization design of forming process parameters and subsequent die wear life analysis, and saves a lot of test costs.
(4) Die cavity stress concentration and temperature cold and hot cycle are the two main causes of die fatigue failure. Therefore, the effects of forming process parameters and die cavity geometry parameters on die temperature field and stress field are analyzed. The combination of simulation analysis method and die fatigue life estimation provides an effective way for die geometry optimization and forming process parameter optimization. The die fatigue life estimated by the local stress-strain method to reflect the die strength is more rational and intuitive than the direct use of the die stress level, which can put forward some constructive suggestions for the actual production, and provide a certain basis for analyzing the causes of the crack of the die, so as to improve the service life of the die.