Through a large number of numerical simulation experiments, on the basis of the theoretical calculation size of the ring blank, three groups of data are selected according to the principle of volume invariance to carry out the numerical simulation of ring rolling forming. According to the analysis of the stress and strain distribution according to the simulation results, it is concluded that the step and fillet contact with the ring blank first, and the stress and strain are generated first. With the downward feeding of the driving roller, the stress area expands, and the deformation area increases, According to the above conclusion, the internal strain of the ring is greater than that of the overall forming part, and the internal stress of the ring shall be in accordance with the above conclusion. Furthermore, the forming dimensions and forming conditions of the three schemes are compared respectively. The forming forging size of scheme I is slightly smaller than the required size of the actual forging, and the fillet is not filled with defects. The forming forging size of scheme III meets the requirements, but there is a “fishtail” phenomenon on the side. Finally, the ring blank size of scheme II is selected as the best size.
Based on the single piece ring rolling process, the forming process of two-piece ring rolling is numerically simulated, and the double ring is successfully rolled. It is concluded that the stress and strain distribution of two-piece ring rolling conforms to the deformation law, the forming size meets the requirements of forgings, and the forming condition is good.
The economic comparison results of single and double ring rolling process show that the blank weight of spiral bevel gear blank formed by single ring rolling process is 2.85kg, the forging weight is 2.62kg, and the material utilization rate is 91.9%. The blank weight of single spiral bevel gear formed by two-piece ring rolling process is 2.75kg, the forging weight is 2.6kg, and the utilization rate of blank is 94.5%. Compared with the one-piece ring rolling forming process, the material utilization rate of the two-piece ring rolling forming process is improved, and the production efficiency is improved and the cost is reduced. The proposal of this process provides a certain theoretical basis for its application in production practice in the future.