Based on the analysis of the forging process of the double spiral bevel gear of an automobile, the forming process of the double spiral bevel gear is put forward. With the help of DEFORM-3D finite element numerical simulation software, the forming process scheme of double split precision forging is numerically simulated, and compared with the forming process scheme of internal split precision forging, it can be found that it is feasible to form spiral bevel gear by double split precision forging. Through the research on the metal forming characteristics of double split precision forging of spiral bevel gear, the influence relationship of various process parameters on the tooth shape filling and forming force of spiral bevel gear is obtained, and the best process parameters are determined. According to the forming characteristics of final forgings, the process scheme of cold finishing tooth profile of spiral bevel gear is put forward, the metal flow law, stress-strain division law and the change law of forming force in the process of cold finishing are analyzed, and the scheme of split flow finishing at the tooth top of spiral bevel gear is further put forward. Finally, the correctness of the process scheme and the selection of process parameters are verified by experimental methods, and compared with the numerical simulation results to verify the accuracy of the simulation results.
The forming process of the double split precision forging process is numerically simulated by using DEFORM-3D finite element software. The simulation results are analyzed and compared with the inner split precision forging process. It is concluded that it is feasible to form the spiral bevel gear by using the double split precision forging method, the material can completely fill the tooth cavity of the spiral bevel gear, and the tooth shape of the spiral bevel gear is full. The double split flow precision forging method can effectively reduce the forming force. Compared with the inner split flow precision forging method, the forming force can be reduced by 12.56%.
Through the numerical simulation results, the die structure is designed and tested on the universal material testing machine. The test results show that the selected spiral bevel gear process scheme and process parameters are correct, which verifies the accuracy of the numerical simulation results.