The risk of casting forging compound forming process is controllable and the process predictability is strong; Taking the product part drawing as the starting point, this paper reversely analyzes the forming of each process step and determines the workpiece size of each step. After solving a series of problems, such as the influence of cold precision forging preform tooth shape on cold finishing process, the influence of hot die forging preform tooth shape and taper on hot die forging process, the selection of casting process and the optimization of Pouring Scheme, the optimization of casting process parameters and so on, a complete set of production process is developed, which is economical and efficient The forming process scheme of driven spiral bevel gear with high precision and excellent quality is completely feasible.
- The influence of tooth shape of preform of spiral bevel gear cold precision forging on cold precision forging step is studied. Two tooth profile schemes of uniform diffusion tooth profile and non-uniform diffusion tooth profile are proposed. The cold precision forging process of different sizes of gear blanks with two tooth profile schemes is studied by using DEFORM-3D software, and the optimal tooth profile of cold precision forging preform is determined;
- Study the influence of tooth shape and taper of spiral bevel gear hot die forging preform on closed hot die forging steps. DEFORM-3D software is used to analyze the forming process of gear blanks with different tooth profile dimensions and different taper using approximate trapezoidal tooth profile scheme in hot die forging step; By comparing the metal flow direction and equivalent stress-strain distribution in the forming process of each scheme, the influence law of tooth shape and gear taper on gear hot die forging is studied, and the optimized tooth shape and taper of hot die forging preform are determined;
- Comprehensively analyze the structural characteristics, material composition and quality requirements of spiral bevel gear and the technical requirements of hot die forging steps, and determine the casting process and casting drawing; Design two pouring schemes and calculate the dimensions respectively; AnyCasting software is used to analyze and compare the filling solidification process and defect prediction of gear castings with two pouring schemes, so as to determine the best Pouring Scheme; The effects of different process parameters (pouring temperature and pouring speed) on the forming quality of castings were studied, and the best process parameters were determined.