Process Simulation And Optimum Of Rotary Forging In The Blank Of Straight Tooth Bevel Gear

Rotary roll is a new technology that applied in partly presswork succession plasticity forming. The cold rotary forging used in straight tooth bevel gear is an advanced technique which used in gear processing. It has a good many merits, such as high material utilization, high productivity, low manufacturing cost, high gear mechanical property, high service life and high forming dimensional accuracy etc. It widely applied in gear processing.This thesis based on the research of the rotary forging in straight tooth bevel gear technology. Finite element analysis is employed to research the process of cool rotary forging in differential satellite gear. The statuses of strain and stress, metal flow rule and force-time curve are obtained and reveal the deformation characteristic. And importantly, the influence of blanks on bevel gear was obtained.The straight tooth bevel gear's rotary roll model has been created in three-dimensional molding software UG and pro/e based on its prototype. The models which will be used in DEF0RM-3D have been gotten. They're the foundation of finite element analysis in straight tooth bevel gear's rotary roll. The use of some part of UG and pro/e had introduced in the thesis, such as mold design,Feasibility/Optimization.The models of finite element analysis used in straight tooth bevel gear's rotary roll have been created based on the rigid plasticity finite element theory. The statuses of strain and stress, metal flow rule have been gotten based on the three-dimensional simulation software DEF0RM-3D by the use of rigid plasticity finite element analysis. The deformation process, equivalent stresses, equivalent strains are showed by figure and curve. And the deformation rulers have been gotten. The simulation results show that filling condition is ideal when the blank is drum shape, and the ideal shape of drum had been designed.In the article, the parameterαis used to express the drum shape, the optimization of drum shape was further studied on the basis of the result obtained before, change the value of and run the numerical simulation of finite element under the same technological parameter, the purposes of the study is to get the forming rules and the influence on the bevel gear when changing the. The minimal total load and the minimal effect strength are selected as objective function, we analyzed the total load curve and the maximal effect stress of die curve, and we obtained the formula about the total load and the maximal effect stress of die.α=1.6 is the optimization parameter finally.