Application of precision forging technology for spur bevel gears

The UG software is used to design the part drawing and forging drawing of the spur bevel gear and the three-dimensional modeling of the forming die. The Defrom-3D software is used to simulate the precision forging process of the spur bevel gear. With the help of the orthogonal test method, the simulation scheme is planned, the optimized process combination is obtained, and the optimized process parameters are simulated and analyzed in detail, At the same time, the influence of die elastic deformation and forging elastic recovery on tooth profile accuracy is analyzed, and then the precise design of die cavity for precise forming of spur bevel gear is realized by reverse compensation.

1). Part drawing, forging drawing and die design of spur bevel gear

Select a common differential planetary gear as the research object, use to carry out the three-dimensional design of the part drawing, and carry out the forging drawing design and die design according to the selected closed forging process requirements and forging drawing design criteria.

2). Numerical simulation of precision forging process of spur bevel gear

The orthogonal test method is used to design the four factor and three-level test scheme, the software is used to simulate the forging process, the factors affecting the forming of bevel gears are optimized, and the optimal combination of process parameters is selected for finite element simulation analysis.

3). Working condition analysis of precision forging die for spur bevel gear

The influence of precision forging process design of spur bevel gear on the force and elastic deformation of the die is studied, and the distribution of elastic deformation of the die in the precision forging process of spur bevel gear is obtained.

4). Elastic recovery analysis of straight bevel gear forgings

Based on the model of the forging and ejection mechanism at the end of cold precision forging, the elastic recovery process of bevel gear after cold precision forging is simulated and analyzed, and the change law of tooth shape size in the elastic recovery process of bevel gear cold precision forging is obtained.

5). Precise design method of die cavity for precision forging of spur bevel gear

According to the results of die elastic deformation analysis and dimension change analysis during forging cooling process, the theoretical model of precise design of bevel gear precision forging die cavity dimension is established, and the method of realizing precise design of tooth profile cavity is given.

Taking the closed precision forging of a certain size spur bevel gear as the research object, the influence of various process parameters on the precision forging of gears is analyzed, and the reasonable process parameters are selected to formulate the process route; The stress, strain distribution, strain rate distribution and load stroke curve of each deformation stage are obtained, and the metal flow law and tooth filling form are analyzed; Extract the dimension change caused by the elastic-plastic deformation of bevel gear forgings, analyze and obtain its law, build the dimension compensation for forgings, and design a reasonable final forging die cavity size.

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