Spiral bevel gear is the key part of the main reducer of automobile rear axle. Its main function is to change the rotation direction of power transmission. China’s automobile industry is developing rapidly, its production and sales are in a booming stage, and the demand for driven spiral bevel gear is increasing day by day. Precision forming spiral bevel gear can not only improve production efficiency and meet the requirements of mass production, but also greatly improve the utilization rate of materials and comprehensive mechanical properties, which is in line with the new road of scientific socialist economic development – environmental protection. Because the tooth surface of spiral bevel gear is arc-shaped, the flow path of metal in the forming process is complex, it is not easy to fill the mold cavity, and the product quality is not easy to be guaranteed. In order to ensure the forming quality of products, more volumes of blank are required, resulting in excessive forming force, resulting in the rupture of the mold and shortening the service life of the mold. Therefore, determining the reasonable process scheme and selecting the best process parameters are the key to the precision forging of spiral bevel gear parts.
According to the structural drawing of driven spiral bevel gear of automobile rear axle, the forging drawing suitable for direct forming of precision forging is designed. Based on the structural characteristics of parts, the forming process scheme of double split precision forging is put forward. The forming process of the process scheme is numerically simulated by DEFORM-3D finite element software. The simulation results are analyzed and compared with the internal split precision forging process scheme. The following conclusions are obtained:
1) It is feasible to form spiral bevel gear by double split precision forging method. The material can completely fill the tooth cavity and the tooth shape is full.
2) The double split flow precision forging method can effectively reduce the forming force. Compared with the inner split flow precision forging method, the forming force can be reduced by 12.56%.