Application of numerical simulation technology in spur gear precision forging

The volume forming of metal is a complex plastic large deformation process. There are geometric nonlinearity caused by large deformation (nonlinearity between strain and displacement), nonlinearity of constitutive relationship of material in plastic deformation state (nonlinearity between stress and strain), and nonlinearity of boundary conditions. In the past, it was difficult to accurately solve the volume forming problem. General numerical analysis methods such as slip line method, energy method and N-S method are usually used. At the same time, a lot of simplification and assumptions need to be made, which often leads to a long distance between the analysis results and the actual situation, and can not meet the needs of theoretical analysis and engineering practice when solving complex problems. With the rapid development of finite element theory and computer technology, the application of numerical simulation technology in metal plastic forming analysis has attracted more and more attention.

In the 21st century, with the rapid development of computer technology, finite element numerical simulation technology has gradually become a powerful tool to analyze complex forming processes. Through the finite element numerical simulation of spur gear precision forging process, the stress-strain distribution, forming load distribution, material flow distribution, geometric dimension change and formed part defects in the deformation process can be obtained. These data can be used to analyze and evaluate the precision forging process and die design of spur gear, and also provide a practical and effective basis for the final determination of forming scheme and the selection of process parameters. Therefore, finite element numerical simulation technology has become one of the most effective methods to analyze the precision forging process of spur gear, verify the design scheme and optimize the process and die parameters.

The finite element method has the remarkable advantages of high boundary fitting accuracy, providing rich element types, comprehensively considering the influence of various factors on the forming process, and providing similar deformation mechanics information under less assumptions. The analysis of metal plastic forming problems is not limited by specific forming problems, and is suitable for the analysis of various metal plastic forming processes.

Doege studied the forging process of spur gear by finite element method, and obtained the relevant data of axial shrinkage and radial shrinkage of tooth profile in the cooling process after forging.

Tb. Herlan uses ANSYS software and finite element analysis method to optimize the tooth geometry, gives the die stress diagram of FEM analysis and the optimized tooth shape, carries out fatigue test on the precision forged spur gear, and compares it with the spur gear produced by traditional technology.

Yoon analyzed the forging process of spur gear by rigid plastic finite element method, and obtained the load stroke curve in the deformation process.

Szentmihali et al. Used the finite element software forge3 to carry out the finite element analysis of the spur gear formed by cold forging with thick wall hollow blank, and obtained the equal effect deformation distribution in the deformation body at the end of cold forging.

Yang used the modular method to analyze the forging process of spur gear, and obtained the force stroke curve, the change of blank shape, the equal effect deformation distribution and the average stress distribution in the deformation body.

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