The ring rolling process of driven spiral bevel gear blank of automobile rear axle is analyzed. The forming of spiral bevel gear blank belongs to plastic forming, so the rigid plastic finite element simulation analysis should be carried out for the ring rolling process.
Rigid plastic finite element method mainly analyzes plastic deformation. Because most of the deformation produced by metal material forming now belongs to permanent deformation (plastic deformation), this theory is recognized and applied by more and more people. The rigid plastic finite element method can not only truly and intuitively show the forming process of spiral bevel gear blank, but also calculate the volume, applied load and energy consumption of spiral bevel gear blank, and clearly show the temperature distribution, metal flow distribution, stress-strain distribution and so on. Because this finite element method has many advantages, the combination with computer will bring great convenience to the test operation. At the same time, it can also intuitively observe various problems in the forming process, so as to make targeted improvement, improve the die design and optimize the process scheme. Therefore, the finite element simulation method has great practical significance.
The rigid plastic finite element method adopts the iterative method, that is, the calculation results of the latter step are calculated based on the results of the previous step. The calculation increment of each step is set before the simulation operation, and the increment value is very small. This kind of calculation is the process of using the small deformation method to achieve the effect of large deformation through the accumulation of quantity. Rigid plastic finite element method is an effective method to analyze metal plastic deformation. DEFORM-3D software analyzes the forming deformation through this finite element method.
While rigid plastic finite element method has many advantages, it also has some disadvantages in deformation analysis. Because in practice, when the material is plastic deformed, the plastic deformation area of the deformed part is much larger than the elastic deformation area, the elastic deformation is ignored in the rigid plastic finite element simulation, which makes the deformation analysis limited to the plastic deformation area, and the stress, strain and stress conditions in the elastic deformation area are not known. Even so, rigid plastic finite element method is still the most effective method to deal with plastic deformation.