The two-piece spiral bevel gear blank has been successfully formed by using the finite element numerical simulation method. In order to illustrate that this new forming process is effective and has many advantages, it should be compared with the optimal forming process scheme of spiral bevel gear blank (one-piece ring rolling process). Because the cost investment in actual production is the main factor for the factory to select the process scheme, this paper will The forming process economy of two-piece ring rolling is compared and analyzed. Material cost and equipment cost are the main aspects of production cost. The following will analyze the utilization rate of materials and equipment. The material utilization rate of single spiral bevel gear blank formed by single and double ring rolling process is shown in Table 1.
| Project | Number | Forging weight / kg | Blank weight / kg | Blank utilization% |
| Single ring gear blank | 1 | 2.62 | 2.85 | 91.9 |
| Two ring gear blank | 1 | 2.6 | 2.75 | 94.5 |
It can be seen from the table that the material utilization rate of gear blank formed by single ring rolling process is 91.9%. The material utilization rate of single gear blank formed by two-piece ring rolling process is 94.5%. Since the thickness of the punching connecting skin formed by the two-piece rolling ring is 5mm, and the thickness of the punching connecting skin formed by the single piece rolling ring is also 5mm, compared with the single piece rolling ring, the thickness of the connecting skin of the single gear blank formed by the two-piece rolling ring is reduced by 2.5mm, which improves the material utilization rate. In addition, the two-piece ring rolling process forms two gear blanks at one time, which improves the production efficiency and reduces the cost.
The optimization of any process is for the purpose of saving cost. Material utilization is one of them, and equipment cost is also an important item in the cost. The comparison of process energy consumption is shown in Table 2.
| Project | Blanking specification (mm) | Initial forging temperature (℃) | Use equipment |
| Single ring gear blank | Ф65×108 | 1150 | Air die forging hammer D51-250c ring rolling machine |
| Two ring gear blank | Ф80×139 | 1150 | Air die forging hammer D51-250k ring rolling machine |
It can be seen from the table that the two-piece ring rolling forming process uses a larger equipment tonnage than the one-piece ring rolling forming process, which increases a turning process, but it has high production efficiency, saves time and reduces cost, which is of practical significance.