Study On The Simulation Of Forming Process And Optimization Of Technology Of Besides-star Wheel

Die design and manufacture is the key of pfinisicity process technics, which directly decide the quality of part. Conventional die design and manufacture is a trial and error course, so it results in prolonged developing period and increased the cost because it needs through and through several times of design, manufacture, trial-manufacture and modification. CAD/CAM is a key technology to realize the automation of product designing and manufacturing. The quality of product can be tangibly improved if the technology is adopted in product designing, engineering analyzing and NC programming in the course of development of product.Besides-star wheel is the most important part of transmission shaft, it's working environment is very complexity; it's performance directly influences the reliability and security of the automobile. The Besides-star wheel if one of slightness axis part, its forming process is difficult. The feasibility, stability,quality of forming (including brimming forming, replicate and organize disfigurement), material utilize efficiency and how to reduce load, how to improve mould life-span of the automobile bending-axis is all emphasized when we working out forming techniques of bent-shaft because of complicated shape and forging technics of bending-axis. In this paper, several key techniques of bending-shaft is simulated by DEF0RM3D (a FEM software), the effect of bill diameter, burr groove structure and friction gene on forming quality and the flowing and strain stress distributing disciplinarian of metal material are particular analyzed. The disfigurement occurred in the forming course is forecasted, eliminated forming disciplinarian and optimized technics parameter and mould structure through numerical simulation. In the practice production, the correctness and the validity of technics scheme and the rationality of mould design is attained practice proved. The theory of precision forging, technology of FEM simulation and mould CAD/CAM are integrated through this research, which helps to shorten developing period, prolong life-span of die, and cut down the cost, etc. The progeny of the research can provide accordance for other bevel gears' producing.Using UC1 steel as experiment material ,physical experimentation has been carried out by means of the machine of DaJiangXinDa vehicle Co.,Ltd. A good agreement of numerical simulation result and physical experimentation results shows that the DEF0RM3D system and its result of the numerical simulation are reliable.