As a typical transmission part, bevel gear is widely used in many industries, such as aviation, aerospace, automobile, instrument and so on. The quality of bevel gear directly affects the performance level of related products. It can be said that the level of bevel gear processing technology has become one of the important symbols to measure a country’s machinery manufacturing level.
At present, the machining of bevel gear in China is still dominated by traditional machining technologies such as gear hobbing, gear shaping, gear shaving and gear grinding. Using these conventional cutting processes, the utilization rate of materials is low, the energy consumption is high, and the productivity is low. In particular, the metal streamline of materials is cut off in the machining process, resulting in the decline of gear tooth strength and fatigue life.
Therefore, in recent years, the application of plastic forming technology to replace the traditional mechanical cutting methods has been paid more and more attention. Precision forming technology overcomes the shortcomings of low material utilization and low productivity in cutting processing technology, especially the low strength caused by cutting off the metal streamline. With its high efficiency and high precision, it has become one of the main methods of bevel gear processing reform.
As an advanced manufacturing technology, precision forming technology is gradually developed on the basis of traditional die forging technology. At present, the generally accepted definition of precision forming process is “at least the dimensional accuracy and shape accuracy of some surfaces of forgings can be directly used for assembly or can be assembled only by grinding”. Using precision forming technology to produce bevel gear parts not only has the significant advantages of material saving, energy saving, reducing machining processes and working hours, low cost and high efficiency, but also can greatly improve the internal and appearance quality of products, which is in line with the process, process theory and method of high efficiency, precision, green and clean. The technology is very complex.
In order to improve the technical and economic level of automobile parts production in China, enhance the market competitiveness of automobile bevel gear products in Hubei Province, and fill the gap of car bevel gear products in Hubei Province, Wuhan University of technology and Hubei car Co., Ltd. jointly applied for the key scientific and technological development plan project of Hubei Province “Fukang car bevel gear cold swing rolling precision forming technology” in 1999, which was approved by Hubei Provincial Science and Technology Commission for project implementation. After nearly two years of process theoretical analysis and experimental research, the cold swing rolling precision forming technology of Fukang car bevel gear has been successfully developed and put into trial production. The product is matched with Fukang car of Shenlong Automobile Co., Ltd.
Based on this project, the cold rotary forging precision forming process of bevel gear is systematically studied, tested, analyzed and summarized, and the process is applied to computer-aided design to develop a targeted computer-aided design system.