Experimental study on double split precision forging of helical gear

Finite element method is widely used in various fields of plastic processing. It is not only an important means to deal with various complex engineering problems, but also an important tool for scientific research. Through the successful application of finite element numerical simulation technology, it overcomes the blindness of traditional “trial and error method”, improves the efficiency of R & D, reduces the consumption of cost, and effectively promotes the modern high-speed development of manufacturing industry. Although finite element analysis has become a numerical “virtual test” to replace the physical test, there is a certain gap between the simulation results and the physical test because the model constructed in the numerical simulation process is simplified and the automatic meshing method is selected. Therefore, combining the actual physical test with the plastic finite element numerical simulation analysis method to verify whether the optimization results of helical gear process scheme and process parameters are reasonable is a powerful means of plastic forming and its theoretical research.

According to the numerical simulation results of helical gear precision forming scheme and the best process parameters obtained from the analysis of helical gear double split precision forming parameters, the lead blank is selected as the test material and verified on the universal material testing machine. The following conclusions are obtained:

1) The forming force of double split precision forging scheme of helical gear is lower than that of internal split precision forging scheme. The lead billet with the same volume and shape is selected. By changing the die structure, the pressure of the universal material testing machine is set to 180kn for experimental forming. The test results show that the tooth shape formed by double shunting is fuller than that formed by internal shunting.

2) The position of helical gear shunting surface is too high or too low, and the tooth shape filling is not full enough. Select the lead blank with the same structure and volume, adjust the die structure to change the position of the diversion surface, and set the test equipment to 180kn for experimental forming. The test results show that the quality of tooth filling is different with the position of the diversion surface.

3) The bevel angle of helical gear preform is too large or too small, and the filling order of tooth profile is different. Lead billets with large cone angle and small cone angle are selected for experimental forming under the condition of ensuring the same volume. Observing the filling of tooth profile, it can be found that when the cone angle is too large, the middle part of tooth profile cannot be filled, when the cone angle is too small, the large end of helical gear tooth profile cannot be filled.

4) The forming law reflected by the test results is consistent with the numerical simulation results.

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