Study On Precision Forging Of Spiral Bevel Gear

Spiral bevel gear is in great demand which apply extensively to the drive axle of vehicle such as automobile,tractor,tank and so on.At present,traditional cutting technology is still adopted in the production of spiral bevel gear.With low production efficiency and bad quality of product,this technology is hard to meet the rapidly growing industry requires of the gear with high performance.So it is extremely essential to develop a new forming technology for spiral bevel gear with the purpose of improve production efficiency and quality of the product.Base on open-die forging process of spiral bevel gear,this paper conduct research on new forming technology,closed forging die design and process parameters.Floating cavity die mechanism was adopted on the new forging die,the product without burrs was achieved,the material utilization was increased.Deforming work method,Slap method and Upper boundary method were combined to establish a mathematical model to compute the deforming force of open-die forging process and closed forging process of spiral bevel gear,the value of deforming force was obtained.UG makes the die 3D moulding and DEFORM-3D simulates the process on precision forging of spiral bevel gear.The metal flowing law with distribution of velocity field,strain field,stress field and temperature field at different stages of forming were discussed,the load-stroke curve was obtained,the deforming force is tally well with theoretical computation.The process parameters was optimized and validated by process experiment.The results shows that when the initial forging temperature is 1150℃,the working speed of press is 200mm/s and the Condition of lubrication is good,the forging of spiral bevel gear with plump tooth and smooth root but without collapse and fold whose performance meet the demand.The die structure is compact,operation is reliable and service life is long.The method of forging die design,computer aid design and numerical simulation are universal and provides reference for the forging process analysis and die design of various gears.