Although a lot of research has been done on precision forging of spiral bevel gears at home and abroad, there are still some problems in the process of applying it to production practice:
- high requirements for moulds. The tooth profile of is complex, which determines that the mold cavity is also complex. Mold processing is difficult and the cost is high.
- the accuracy is difficult to guarantee. The accuracy of the forged gear directly depends on the accuracy of the die cavity. At the same time, there are also factors such as thermal shrinkage deformation and high-temperature oxidation in the forging process, so the accuracy of the forged tooth profile is difficult to ensure.
- precision forging requires large forming force and low die life. The tooth profile of spiral is complex. In order to ensure that the tooth profile is fully filled, the forming force is often large, which will reduce the service life of the die.
At present, most domestic gear manufacturers still use the traditional production process to produce spiral bevel gears. The traditional production process is: blanking, forging blank, rough and fine turning blank, rough and fine milling, heat treatment, fine grinding, inspection and matching. Taking a gear factory in Guangdong as an example, the traditional production process is still used to manufacture spiral bevel gears.
In the forging production of spiral bevel gear blanks, the traditional experience based and experimental methods are still used in die design and process formulation. However, the forging of spiral bevel gear is a three-dimensional unsteady plastic deformation, and the deformation mechanism is very complex. There are not only material nonlinearity, but also geometric nonlinearity, as well as boundary condition nonlinearity. The die design and process formulation based on experience and experiments will lead to a large waste of materials, a large forging energy consumption Poor quality of forgings and high rejection rate.
Therefore, it is of practical significance to study the forging process of spiral bevel gear blanks by numerical simulation on the basis of existing equipment, so as to provide guidance for die design and process formulation.