Finite element analysis of forged gear blank

In the traditional technology, gear processing should go through the processes of blank heat treatment, gear blank processing, tooth profile processing, tooth end processing, tooth surface heat treatment, precision datum correction and tooth profile finishing. In recent years, precision forging has become a new process with good development prospects. Compared with the traditional cutting methods, it can not only improve the material utilization rate of gear processing to more than 70%, the gear strength to more than 20%, but also improve the production efficiency by about 40%. Based on DEFORM-3D finite element software, the numerical simulation of the forging process of forged gear blank is carried out in order to improve the material utilization, better observe the streamline condition in the metal during the forging process of forged gear blank, optimize the forming process scheme of gear and improve the mechanical properties of gear parts.

Based on DEFORM-3D finite element software, the forging process of forged gear blank is numerically simulated, and the following conclusions are obtained:

(1) When the bar diameter is Φ 105mm~ Φ At 120mm, metal reflux is easy to occur in the rim of forged gear blank in the forming process, which is unfavorable to the mechanical properties of forged gear blank.

(2) When the bar diameter is less than Φ At 90mm, in the forming process of gear blank, the hub part is filled with the cavity first, and the rim part is filled with the cavity later. The difference between the two is long, which will lead to uneven equal effect to a certain extent.

(3) When the bar diameter is Φ 90mm~ Φ At 105mm, during the forming process of forged gear blank, there is no metal reflux and folding at the rim, and the forming effect is good, of which the diameter is Φ The forging gear blank formed from 100mm bar is the best in terms of metal fluidity, equivalent strain uniformity and tonnage energy consumption of the press.

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