Application of numerical simulation technology in gear forging

Before the 1990s, the research and production practice of gear forging was mainly based on physical simulation. That is because the numerical simulation method at that time was not perfect in simulating plastic deformation, and was not ideal in predicting metal deformation law and accurately calculating parameters such as stress, strain and temperature. Since the 1990s, with the development of computer software and hardware, numerical simulation methods have made great progress. There are many finite element software and methods that can be used to accurately simulate the plastic deformation process. Many experts and scholars at home and abroad have studied this.

Hung hsiou Hsu used the upper bound element method to study the effects of friction, number of teeth and other parameters on forming force and metal filling effect. Joungung Choi et al. Studied the forging process and die design of spur gears and triangular internal fine teeth by using the upper bound element method. J. H. song et al. Studied the cold forged spur gear, and analyzed the influence of modulus and number of teeth on material deformation mechanism by numerical simulation method. Herian T and others optimized the gear tooth geometry with the finite element software ANSYS, obtained the analyzed die stress diagram and the optimized tooth shape, and tested the fatigue of the gear.

M. H. Sadeghi et al. Studied the forging process of spur and helical gears by using the upper bound element method, obtained the metal flow law and deformation load in the forming process, and studied the effects of parameters such as the number of teeth, modulus, friction and the diameter of blank inner hole on the forming load. The results show that the forming load can be reduced by reducing the friction coefficient, the number of teeth, the modulus and the diameter of the inner hole of the blank. Doege et al. Studied the spur bevel gear with the finite element numerical simulation method, and obtained the relevant data of the radial and axial shrinkage of the gear tooth profile during the cooling process after forging. Yoon et al simulated the forging process of spur bevel gear with numerical simulation method, and obtained the load stroke curve of the forging process.

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