Combined with the practice of ZHY gear, the forging process of driven spiral bevel gear blank is numerically simulated.
In the production of driven spiral bevel gear, the die design and process formulation of ZHY gear depend on the methods of experiment and experience, while the forging process of gear is a very complex process, with nonlinearity in geometry, material and boundary conditions, Depending on experiments and experience, mold design and process formulation often need many physical tests to complete, which leads to the problems of large material waste and high cost.
With the development of plastic forming theory and computer technology, people gradually begin to study the plastic forming of materials by numerical simulation. Through numerical simulation, we can answer the questions that cannot be answered by experimental design and empirical design, and understand the whole process of metal plastic forming, including the situation of material filling die in each stage of metal forming process, material deformation trend, internal stress, strain, strain rate, forming load, velocity vector field and other information.
This has important practical significance for metal plastic forming die design, process design, blank design, press selection and forming quality control. Now, the finite element numerical simulation method is introduced into the research on the forging process of spiral bevel gear blank in this gear factory. The forging and forming of driven spiral bevel gear blank in gear factory includes four steps: heating, upsetting, die forging and punching, and trimming.
Upsetting and die forging are the plastic forming process of the whole processing technology. In the existing literature, the numerical simulation of gear forging process often ignores the upsetting process and only simulates the die forging process, that is, only one-step analysis is carried out. However, one-step analysis can not reflect the influence of residual stress after processing in the previous process on the next process, and can not well reflect the real forging process.
A multi-step analysis method of gear forging process is proposed. Firstly, the upsetting process is numerically simulated to obtain the blank shape, stress field, strain field and temperature field after upsetting, and then the die forging process is numerically simulated on the results of numerical simulation of upsetting process to obtain the final forging shape, stress field, strain field and temperature field.