Research On CAD/CAE Technology Of The Precision Forging Process For Spur Bevel Gear

The tooth of gear named precision forging gear can be formed directly by the forging die without chip-removal machining. Especially for the spur bevel gear,it was the one of precision forging parts which were developed and applied earlier. Compared with the machining gear, some merits can be obtained to the gear made by precision forging technology as high mechanical performance, long life, energy saving and less materials. There are several problems in rapid response manufacturing of the conventional design process, namely longer design period, experience-dependent designing, poorly information sharing, which often results in high rate of disused die, high risk, lack of efficiency, high cost, unexpected design, poor quality. It prevents the development of new automobile severely. Therefore, it is an important subject to shorten the period of die design, improve the efficiency of die production, assure the quality of the die in promoting the development of die enterprise and gear industry. It is an inevitable development trend of gear industry that uses CAD/CAE integration technology in spur bevel gear manufacturing.According to the reality of precision forging gear industry nowadays, using the software UG which is developed by EDS in the US, the dissertation found a practical and feasible CAD system of die design for precision forging gear, and used the analysis software Deform-3D as a platform to simulate the sheet metal forming process. The integration of CAD/CAE technology in precision forging gear die has also been implemented.The dissertation summarized the common CAD designing process of precision forging gear die, and developed a CAD system of die design for spur bevel gear based on UG. This system mainly included four modules such as the tooth form modeling, non- tooth form modeling, mold modeling and precision forging die assembly.The dissertation studied CAE technology for spur bevel gear forging die, and described the key technology of numerical simulation in spur bevel gear forming process. In the case of planetary gear, the dissertation proposed a method of numerical simulation in spur bevel gear forming process, using Deform-3D in several aspects such as the establishing of calculating models, the setting of simulation parameters, simulation results and formability analysis.Finally, the dissertation studied the application of CAD/CAE integration technology of spur bevel gear forging die in the case of axle shaft gear.