Numerical simulation process parameters of helical gear

For a long time, for helical gear designers, the design or development of a process scheme is basically based on production experience. The design is not based on the real flow law and specific flow state of metal in the process of forging or extrusion, but depends on empirical data and empirical formula, and is designed according to estimation and judgment. This kind of helical gear design method based on empirical design has great limitations and lacks reliable basis.

At present, the research on the precision forging process of helical gear at home and abroad mainly focuses on the traditional mechanical analysis methods. These methods have certain limitations for such complex forming process, and can not directly optimize the influencing factors. Due to the requirements of die material, precision machining and equipment capacity, gear precision forging test has the advantages of high cost, long cycle and heavy workload.

In recent years, the numerical simulation method represented by finite element method has been widely used in the solution and analysis of various metal forming problems, and the computer simulation of the whole metal forming process of helical gear has been realized. The application of three-dimensional finite element numerical simulation technology to study the precision forging of helical gear can obtain the plastic deformation behavior, flow law, geometric change, mechanical behavior of material deformation, internal stress and strain distribution of material in the whole deformation process, which provides effective information and necessary technical support for practical process research, design modification and equipment selection.

Firstly, the three-dimensional finite element simulation model of the precision forging process of helical gear is established. Secondly, the closed die forging process of helical gear is numerically simulated and analyzed by using the three-dimensional finite element numerical simulation software DEFORM-3D. The parameters such as temperature, friction factor, modulus, helix angle and cone angle are selected and simulated for many times. According to the simulation results, the effects of the above parameters on the forming process are compared and analyzed, Thus, the influence law of them on the forming process is obtained, which provides an effective basis for the research of precision forging process of helical gear.

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