Casting process design and numerical simulation of spiral bevel gear

As the starting point of casting forging compound forming process, whether the process design of casting process and the control measures of casting defects are reasonable directly affect whether the casting forging compound forming process can be successfully applied in the manufacturing of spiral bevel gear.

  1. Firstly, the casting process of driven spiral bevel gear casting is analyzed, and the casting drawing is formulated according to the specific technical requirements; The influence of the composition and content of casting material 20CrMoH on the casting process is introduced; After comprehensively considering the advantages and disadvantages of each casting process, the material and output of spiral bevel gear, coated sand casting is selected as the casting process of spiral bevel gear blank, and a new type of quartz sand based high temperature resistant cast steel coated sand is selected.
  2. The central top pouring scheme and the common Pouring Scheme of pouring riser are designed, and the dimensions and pouring process parameters of each element and insulation riser of the two pouring schemes are calculated;
  3. Using AnyCasting software, the filling and solidification process of spiral bevel gear casting with central top injection Pouring Scheme and common Pouring Scheme of pouring riser are numerically simulated and analyzed. After comparing and analyzing the filling and solidification process and the distribution of shrinkage cavity defects of the two schemes, it is determined that the central top injection pouring scheme is more suitable for the casting process of coated sand of spiral bevel gear casting;
  4. The effects of pouring temperature and pouring speed on the forming quality of spiral bevel gear blank casting are studied and analyzed: in a certain temperature range (1510 ~ 1640 ℃), the higher the pouring temperature is, the fewer shrinkage defects of spiral bevel gear blank casting are; The optimum pouring temperature is 1640 ℃. The pouring speed has a great influence on the distribution of residual air on the upper surface of the casting. When the pouring speed is 0.8m/s (pouring time is 2.97s), the residual air content on the upper surface of the casting is the smallest and the forming quality is the best. The optimum pouring speed is determined to be 0.8m/s.
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