The cold rotary forging precision forming process of bevel gear is an advanced manufacturing technology. Its process design in actual production includes the preparation of blank, the design of bevel gear forging, the calculation of rotary forging force and the determination of rotary forging machine tonnage, the determination of rotary forging process parameters (including swing head inclination, reduction per turn, rotary forging motion track and other parameters), the design of electrode and concave model cavity. The above problems are analyzed and studied, and the corresponding calculation methods or determination principles of process parameters are put forward. These calculation methods and principles will be the basis for the calculation and decision-making of process aided design in gearcapp system and the determination of geometric relationship in parametric CAD modeling.
The precision forming process theory of bevel gear cold rotary forging is systematically studied. Theoretical analysis and Experimental Research on each process design link (including blank preparation, calculation of rotary rolling force, selection of rotary rolling equipment tonnage, selection of rotary head movement track, determination of rotary head inclination and determination of feed rate per revolution of cone die) are carried out one by one. At the same time, the tooth shape design of tool electrode is analyzed in detail, The geometric dimension accuracy transfer relationship between bevel gear part, concave mold cavity and electrode in the precision forming process of bevel gear cold rotary forging is proposed, and the corresponding calculation formula is deduced. This provides a theoretical basis for the process design and CAD modeling in the later gearcapp system.