Research On Cold Precision Forming Process And Forming Range Of Spur Gear

The spur gear is one of the main forms of mechanical transmission, which arewidely used in a variety of machinery and equipment. The spur gear have higherbearing capacity, longer life, compact structure at work, so it has high qualityrequirements for the stress distribution and filling in the spur gear forming. The spurgears produced by the precision forging, whose metal flowing line continuouslydistributed along the tooth, so it can meet internal stress of the gear and integrity toothrequirements.However, in the cold precision forging of gears, the larger force of forming andtooth side filling shortage are main problems of the spur gear’s forming. To thisproblem, Most scholars have proposed floating die process, shunt forming process, thecombined, one model two hammer, cold closed-die upsetting extrusion process of thespur gear forming and so on. To the problem of spur gear cold precision forging, mostof solutions are based on past experience, and no accurate quantitative relationship.That is to say the spur gear forming range in the cold precision forging is not yet clear.In addition, impact of the limit load of mold on the forming thickness is not clear. Testmethod directly with mold is obviously much higher cost and too much difficulty. Andso, through the finite numerical simulation, we can intuitive predict a regular pattern ofmetal flowing, stress-strain distribution law in forming process, in order to shortresearch time and reduce waste of raw materials in the actual production.With module2of spur gear as an example, this topic is using closed upsetting-hollow shunt, one model two hammer spur gear forming process. That is, the firstorder is pre-forging with activities mandrel ring blank upsetting extrusion, the secondorder is final forging without mandrel shunt forming. And finite element simulationsoftware—DEFORM-3D to simulate spur gear forming process, analysis relationshipbetween gear filling and forming load, and then to verify the process feasibility. And explore the regular pattern of metal flowing and critical point of the shunt hole of gear.Through the analysis of a large number of simulated data, finally experiment gainshaping range curve of spur gear on theory with the limit load, and it may provide afeasible reference for the spur gear forming on future. By a large number of simulatedphenomenon, with the hollow blank closed upsetting-hollow shunt, one model twohammer spur gear forming process, optimize and get formula of the billet volume ofthe spur gear, and there is a lot of sense on improving utilization of the material atactual production.