When the straightsplit wheel blank is cut, the material of the cogging part is removed, and the stress contained in the cogging material disappears, which is the substantive reason for the deformation of the straight bevel gear split wheel blank in the machining. In this paper, the overall deformation state of straight bevel gear blank during machining will be obtained through finite element simulation, and the mapping relationship model of stiffness change residual stress evolution deformation of straight bevel gear blank will be established to analyze the deformation in wheel blank machining. When the results obtained by the two calculation methods are consistent, the design parameters of straight bevel gear blank are changed, and the influence of the change of parameters on the machining deformation of straight bevel gear blank is analyzed.
- The overall deformation of straight bevel gear blank during machining is obtained through finite element simulation. The results show that the main deformation form of straight bevel gear blank is bending deformation, and the z-direction deformation of straight bevel gear blank is obvious. Therefore, in the later research on the deformation of split gear, the direction of deformation mentioned is the thickness direction of straight bevel gear split gear blank.
- The stiffness, stress and deformation of the straight bevel gear split blank are studied as a related whole, and the corresponding mapping mathematical model is established. The calculation results of the mathematical model are analyzed and compared with the finite element simulation results. The results show that the calculation and analysis results are highly consistent with the finite element analysis results and have high reliability, which lays a foundation for the subsequent experimental verification.
- As the thickness of the increases slowly in the process of splitting, the thickness of the straight bevel gear decreases rapidly. Under the condition of minimizing the production cost, it is most appropriate to select the straight bevel gear blank with the thickness of 1.8 times the tooth height.
- The smaller the proportion of the straight bevel gear to cut off the wheel blank, the smaller the deformation of the corresponding split gear, but it will lead to the increase of the workload of gear assembly and the assembly accuracy that is more difficult to control. In order to ensure that the split gear does not deform much and avoid unnecessary assembly workload, the cutting proportion of straight bevel gear split gear blank should be reasonably selected, and the number of teeth contained in the split gear should be controlled between 5 and 8 as far as possible.