Upsetting process of driven spiral bevel gear blank

The upsetting process is upsetting with ordinary flat anvil, and the initial blank bar size of driven spiral bevel gear is Φ 160mmx342mm. In the upsetting process of spiral bevel gear blank, this blank is forged into a drum with a height of 81mm. The upsetting feed amount (i.e. reduction amount) of spiral bevel gear blank is 261mm before and after upsetting.

X	Y	R	X	Y	R
0	0	0	0	0	0
50	0	0	50	0	0
88	38	0	88	-38	0
150	38	0	150	-38	0
210	25.25	0	210	-25,25	0
210	80	0	210	-80	0
0	80	0	0	-80	0
0	0	0	0	0	0

In DEFORM-2D, the geometric models of blank and upper and lower cutting boards input in the forming module are shown in Fig. 1 (a) and 1 (b) respectively. The blank size is φ 160mm × 342mm, and the upper and lower cutting boards can be simplified to size φ 400mm × 50mm round plate. The cutting board and blank are symmetrical models. In order to shorten the calculation time, 1 / 2 simulation is taken. DEFORM-2D has its own modeling function. Due to the simple structure of the blank and the upper and lower cutting boards, select the cylinder in the define primitive geometry of DEFORM-2D and input its bottom radius and height values respectively. The initial mesh of the simulated bar blank upsetting is divided into 5000 elements. Because the ring blank making process is relatively simple and the temperature field of the die is not analyzed, the die mesh is not divided in the ring blank making process.

The initial diagram and completion diagram of DEFORM-2D upsetting process are shown in Fig. 2 (a) and Fig. 2 (b) respectively. During the upsetting deformation of spiral bevel gear blank, the height of spiral bevel gear blank decreases rapidly in a short time, the spiral bevel gear blank material has a wide range of radial and axial flow, and the outer surface of spiral bevel gear blank also changes from the initial regular annular surface to the final drum surface.