Research On Bevel Gears Forming Technology And Precision Control

In recent years the auto industry is developing rapidly, and the rising demand for gear.But traditional cutting processing had low material utilization ratio, low productionefficiency, it is do not accord with sustainable development. Precise forging formingtechnology had more material utilization rate, higher the production efficiency, producedbetter quality than the former. So precise forging forming technology to replace traditionalcutting processing has is imperative. This paper used a3d elastic-plastic finite elementsimulation method with bevel gear precision cold forging process simulation, got relateddeformation data of mould and forging.Bevel gear precision cold forging forming resistance was great, when the process offorming die would produce elastic deformation, and forging leave the mould after formingthat happened elastic rebound, this two kinds of elastic deformation behavior had theenormous influence for the accuracy of precision cold forging. This paper is committed toimprove the accuracy of precision cold forging bevel gear, though the compensation of themold cavity correction method to eliminate the influence of their forgings, obtained thefinal accord with the requirement accuracy of forgings bevel gears. The main works:First of all, the B sample build tooth shape curved surface, then completed the3dmodel of bevel gears, at the same time, designed bevel gear forgings model and moldcavity, achieved their parametric design. Second, set up two levels of moulds concavedie structure and optimized it, accomplished the design of die structure, created the finiteelement model, determined the best process parameters. The paper also puts forward a newprocess, it was closed and opened die forging organic unifies in together, drop off formingload, made a good result. Then, after numerical simulation, done data processing formodels, got the elastic deformation law of mold cavity and the flexibility spring back ruleof the bevel gear forgings, plot Final tooth shape curve before and after deformationcontrast figure, according to the deviation of the bevel gear forgings, done iterative thecompensation correction for the mold cavity, got the best of the form. Finally, found outthe best form and coordinates relationship, and fitted out law straight line equation,numerical simulation provided convenience to repair the form for practical production.Research shows that the elastic deformation of the mold cavity and elastic rebound offorgings have great influence on the accuracy, of which the mold cavity elasticdeformation amount plays a main role. Through the compensation correction method caneffectively increase the bevel gears forming quality of precision cold forging, andeffective fast, the cost is low. The finite element numerical simulation to make the theoryreference basis for the practice production, greatly shorten the mould manufacturing anddebugging cycle.