Due to the high cost of precision forming and high requirements for equipment, the production method of plastic forming blank first and then gear cutting is still adopted in China. The production process of driven spiral bevel gear blank is related to the subsequent tooth cutting process of driven spiral bevel gear. The whole plastic forming process of driven spiral bevel gear blank mainly includes three processes: ring blank making, ring rolling and final forging.
The shape of the die and the forming cavity in each step are related to the utilization rate of materials, filling condition and the quality of formed parts in the plastic forming process. Accurate design of preforms and their dies in plastic forming process is of great significance to improve material utilization and shorten design cycle. Taking a certain type of driven spiral bevel gear blank as the research object, this paper simulates the whole manufacturing process, and accurately designs the shape of preform and die in each step.
(1) On the basis of previous studies, considering the volume loss and volume reservation of hot forging, the preform design and die design are carried out for the whole plastic forming process of toothless blank of driven spiral bevel gear. The size and shape of preform and die cavity in each step are introduced. The whole process is simulated by CAE software DEFORM. The difference between the simulation results of preform and the actual design size is small, Meet the requirements of subsequent gear cutting of driven spiral bevel gear blank. At the same time, it provides reference and suggestions for the die design and process design of similar ring parts in the future.
(2) This paper introduces the equipment selection and basic forming parameters of the plastic forming process of driven spiral bevel gear blank. The equipment selection includes the equipment selection and introduction of ring rolling process and closed die forging process. The basic forming parameters of the process include the forming parameters of each step of ring blank making process, ring rolling process and closed die forging process. The finite element results show that the selection of equipment is appropriate, and the basic forming parameters of the process are also in the appropriate range.
(3) The streamline change process of each step in the ring blank making process is analyzed. The streamline distribution in the whole process is good, and no streamline folding is found, which can provide good preforms for the subsequent ring rolling process and closed die forging process.