Application of numerical simulation in cylindrical gear blank forming

The development of traditional cylindrical gear forming technology is a process through repeated tests by operators and years of experience accumulated by technicians. This research method is not scientific, consumes raw materials, wears molds and wastes time, and is no longer in line with the purpose of saving energy and materials. Therefore, in order to save time, reduce investment and save materials, ring rolling forming technology and numerical simulation technology are combined to simulate the whole plastic forming process through simulation software, which meets the needs of today’s market.

At present, researchers at home and abroad have conducted in-depth research on this technology. Zhao Chunyu and others studied the numerical simulation of the die forging process of typical cylindrical gear blank in the machinery industry, and compared and analyzed the forming process of cylindrical gear blank from the following aspects: the influence of the pressing speed of the upper die on the forging, the influence of the workpiece temperature on the simulation, the influence of friction conditions on the stroke load, and the influence of the bridge fillet of the die flash on the die in the forging process, Thus, the optimal process scheme is obtained: the initial forging temperature of the workpiece is 1000 ℃, the pressing speed of the upper die is 1000mm / s, the fillet of the flash bridge of the die is 2mm, the friction condition between objects is shear friction, and hot forging is followed. The results show that the pressing speed of the upper die, the temperature of the workpiece, the friction conditions and the bridge fillet of the die flash all have effects on the die forging.

D. Y. Yang numerically simulated the forming process of cylindrical gear rolling by finite element method, studied the plane deformation in the machining process, obtained the velocity field and surface external force of metal, and calculated the strain rate distribution. N. Kim and Y. yea also adopted the finite element simulation method for the cylindrical gear rolling process, and played a certain role in promoting the introduction of numerical simulation into the cylindrical gear forming. Then, when studying the numerical simulation of cylindrical gear rolling process, N. Kim improved the meshing of ring blank and used two meshing methods. The results show that this improved method reduces the amount of simulation calculation and improves the running speed. Z.M.Hua. Pilliger et al. Studied the finite element numerical simulation of cylindrical gear forming, and the results well predicted the “fishtail” phenomenon in the forming process. K. Sawamiphadi and h. Utsunomiya, through a large number of numerical simulation experiments, finally obtained the values of various parameters in cylindrical gear forming. The accurate values are conducive to improve the simulation running speed, which is of great significance.

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