Research On Deformation Of Spiral Bevel Gears With Double Rollers Rotary Forging

Double rollers rotary forging is a new process developed on the basis of ordinary rotary forging.Which is partial deformation of the blank with a pair of symmetrical rolls.The new process is suitable for forming ring,disk forgings and forming complex gear forgings.Screw driven bevel gear is the main transmission components of automobile main reducer,it has been widely applied in automobiles,tractors,construction vehicles,military vehicles and other mobile machanical systems,the diameter of driven spiral bevel gear larger,the diameter is usually 170⁵00mm,forging equipment with the general shape forging methods needs for 20000kN¹00000 kN heavy tonnage of forging and pressing equipment to forge the driven spiral bevel gear.It only needs for 2000kN¹0000 kN tonnage of equipment using double rollers rotary forging precision forming process to forge the driven spiral bevel gear.In this paper,the mold structure design of a double rollers rotary forging spiral bevel gear is completed,and the movement principle of the mold is analyzed.The 3D modeling and virtual assembly of parts have been completed,and the thermo-mechanical coupling of metal thermoplastic deformation is also analyzed,The dynamic recrystallization model of the metal has been established,the key condition of numerical simulation has been managed reasonably.Using UG 3D modeling software,3D finite element model of double rollers rotary forging spiral bevel gear has been established.The simulation software of DEFORM-3D has been used to simulate the forming process.And the results of the simulation were analyzed,the deformation law of the forming load,the temperature field,the metal flow velocity field,the equal effect stress field,the equal effect strain field,the damage factor distribution,the filling degree of the tooth shape and the grain size during the double rollers rotary forging process were analyzed.In this paper,the orthogonal test method was applied to the effective analysis of the double rollers rotary forging spiral bevel gear.5 factors which are the initial temperature of the blank,the feed rate of the lower die,the coefficient of friction,the rotation speed of the pendulum,the thickness of the blank,and 4 levels are determined.The process schemes were selected by using the type L₁₆?4⁵?orthogonal tableorthogonal table,and simulated by using DEFORM-3D software.The optimal process parameters are obtained by a comprehensive comparison of the simulation results,that is,the optimal scheme was A3B2C1D2E3.The experiments of double rollers rotary forging automobile driven spiral bevel gear were done,and the results were compared with the simulation results,which indicated that the numerical simulations were reasonable.And the process scheme obviously improved the tooth filing degree.The microstructure evolution of double rollers rotary forging spiral bevel gear,isothermal normalizing and surface carburizing and quenching were analyzed.The results turned out that the microstructure of spiral bevel gear with double rollers rotary forging was better than that of cutting gear...