Precision plastic forming process of automotive driving spiral bevel gear blank

As one of the core parts of the automobile drive axle, the driving spiral bevel gear is easy to be damaged due to its small number of teeth and large bearing force in work. The stability and maturity of its preform production process have a direct impact on the quality of later formed teeth. In recent years, there are many processes for producing driving spiral bevel gear blank in China. However, each process has different characteristics. The quality of active spiral bevel gear blanks produced by various processes is also uneven. In order to improve the stability of the process, improve the utilization rate of materials and production efficiency, reduce the defective rate, save production costs and reduce energy consumption. Under the leadership of the teacher, it is proposed to analyze the problems existing in various existing production processes and put forward corresponding improvement schemes. At the same time, the feasibility experiment analysis of extrusion closed die forging process is carried out.

Firstly, CATIA modeling is used, and then deform finite element analysis software is used to simulate the forming process of two main domestic driving spiral bevel gear blanks. Analyze the metal flow in the forming process, whether there is folding, and the stress and strain of each part. According to the unreasonable defects and problems found, the improvement scheme is put forward, and the simulation is carried out again until the molding results meet the reasonable requirements. Figure 1 and Figure 2 are the gear product diagram corresponding to the driving spiral bevel gear blank and the driving spiral bevel gear blank to be studied in this paper.

The gear blank shown in Fig. 2 is only a rough blank diagram for the driving spiral bevel gear shown in Fig. 1 that needs to be formed finally. According to the characteristics of different forming processes and the focus of different process research, the shape of the gear blank shown in Figure 2 will be modified to adapt to different forming processes, so as to achieve the best quality and highest economic value of the final production of the driving spiral bevel gear. The products shown in Figure 2 formed by three forming processes will be studied. The three processes are: ① cross wedge rolling; ② Cross wedge rolling closed die forging; ③ Extrusion closed die forging.

By studying the forming process of driving spiral bevel gear blank, the main problems existing in the current process are analyzed, and the corresponding solutions are put forward to guide the practical production. Through the process improvement, the defects such as folding, excessive stress, microcrack and residual stress in the forming process of gear blank are reduced, the utilization rate of materials is improved, and the energy consumption in the processing process is reduced. Through the simulation analysis of each process, we can track and understand the metal flow and stress-strain of gear blank in the forming process in detail, and then combined with the corresponding plastic forming theoretical knowledge to provide guidance for enterprises to avoid such problems in the production process, improve the forming process and improve the product quality. Due to the great popularity of automobiles in recent years, the demand for driving spiral bevel gear blank is also rising sharply. Through the research of this paper and the improvement of related processes, we can not only improve the product quality, but also improve the utilization rate of boundary materials of single product, so as to reduce the production cost of enterprises and produce great economic and social benefits.

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