Numerical Simulation On Forging Technology Of Spiral Bevel Gear Blank

Spiral bevel gear is a kind of gear with complex tooth shape,high transmission efficiency.stable transmission ratio and high bearing capacity.lt is widely used in automotive,aerospace.engineering machinery and other industries.As the core of the mechanical equipment industry parts,the manufacturing level of spiral bevel gears, to a certain extent, represents a national mechanical equipment industry development level.At present, the production of spiral bevel gears still rely on the traditional way-"hot forging+machining" in our country.How to improve production efficiency and manufacturing quality on the basis of the existing equipment is the question that the enterprise concern about.The research content of this paper is based on that demand of the enterprise.Many-steps analysis method is put forward to simulate the forging process of spiral bevel gear blank.The finite element software DEFORM-3D is used to simulate the pull long process and die forging process of driving spiral bevel gear blank and the upsetting process and die forging process of driven spiral bevel gear blank. The metal flow law of forging process, the curves of stress,strain and temperature changing with time throughout the forging process, the stress,strain and temperature distributions when the forging process is completed, and the stroke-load curves and the step-energy curves of forging process are got. The results show that the stress and strain are great and the temperature is high in the ladder place,because the metal flow difficultly in the ladder places.The effect that die structure, initial forging temperature and friction coefficient on forging are researched.The die structures are improved.The forging processes when the die structures have been improved are simulated.And the stress,strain and temperature distributions are compared before and after the die structures are improved. The results show that the forming quality of forgings are improved due to the die structures are improved. The results of numerical simulation can provide guidance for the die structure design and improvement. The forging processes are simulated when the initial forging temperature is1000℃,1050℃,1100℃and the friction coefficient is0.3,0.7.The numerical simulation results are compared. The results show that when the initial forging temperature is higher and the friction coefficient is less.the stress.strain.temperature.load and energy are lower.Squeezing forming method is proposed to solve the problem of forgings bent because of the problem happening in free forging of driving spiral bevel gear blank. DEFORM-3D software is used to simulate the squeezing forming process. The blank shape, stress,strain and temperature distributions after squeezing forming are got.and the squeezing forming process is simulated together with the die forging process. The problem of forgings bent is solved.But the production efficiency of squeezing forming method is low and the energy consumption is high,so spinning forming method is proposed.A spinning device is designed for spinning forming.3d modeling software SOLIDWORKS is used to establish the geometric model of spinning device.and the finite element software ABAQUS is used to simulate the spinning forming process.The blank shape, stress rainbow and strain rainbow after spinning forming are got.The free forging can be replaced by spinning forming.The energy consumption of squeezing forming and spinning forming are compared.the spinning forming is less.