1) Design of precision forging process of helical gear. According to the principle of precision forging and the structural characteristics of helical gear parts, a double split precision forging process scheme is proposed. With the help of finite element numerical simulation software DEFORM-3D, the numerical simulation analysis is carried out. Compared with the traditional internal split forging process scheme, it is proved that the process scheme is feasible.
2) Study on forming characteristics of double split precision forging of helical gear. According to the process characteristics of helical gear double split precision forging, the finite element model is established, and the numerical simulation analysis is carried out. The metal flow law, stress-strain distribution law and the influence law of process parameters on metal flow in the process of helical gear precision forging are obtained, and the best process parameters are determined.
3) Study on cold finishing of helical gear teeth. Based on the compound forming process of hot forging and cold finishing, the finishing quantity of tooth profile is studied, the forming process of finishing tooth profile is analyzed, and the die structure is optimized.
4) Experimental study. According to the results of theoretical analysis and numerical simulation, the helical gear test die is designed and manufactured. The lead blank is selected as the test material and tested on the universal material testing machine to verify the results of theoretical analysis and numerical simulation.