Due to the characteristics of rotary forging process, its motion form is different from traditional forging and has its particularity and complexity. It is difficult to understand and analyze the flow law of metal and the distribution law of die stress through specific experiments.
The three-dimensional modeling software Pro / E is used to model the rotary forging die and straight tooth conical parts. The rotary forging process of straight tooth conical gear is analyzed by using the finite element digital simulation analysis method with the software from-3d. The forming law of straight tooth conical gear and the law of the influence of blank shape on its forming are summarized. The specific research progress and results are as follows:
(1) The large-scale three-dimensional modeling software is used to model the spur bevel gear prototype and die prototype. The assembly is carried out according to the rotary forging principle, and the physical model of spur bevel gear rotary forging is obtained, which provides a basis for the later finite element analysis.
(2) According to the rigid plastic finite element theory, the swing rolling forming process of spur bevel gear is analyzed by using the finite element simulation software Defrom-3D. The process of metal filling the die cavity is divided into three stages for detailed analysis. The metal flow law, filling law and stress-strain distribution cloud in the forming process are obtained. The influence of blank shape on its forming is emphatically compared and discussed. It is concluded that the drum blank is most conducive to the forming of spur bevel gear.
(3) Based on the in-depth analysis and Research on the drum blank, the minimum total energy consumption and the minimum maximum equivalent stress of the female die are selected as the optimization objectives α The relationship between the maximum equivalent stress and α The total energy consumption of rotary forging, the maximum equivalent stress of female die and α Function expression for. By synthesizing the two curve functions, the optimal bulge degree of drum blank is obtained α= 1.6。