Direct Extrusion Forming Parametric Analysis Of Spur Gear And Process Optimization

The traditional manufacture technology of gear is cutting which has low productivityand wastes lots of materials. So the paper put forward cold forging technology program ofstraight gear. The paper did some researches on the related technology of cold forging ofspur gear.This paper discussed the technology characteristic of the plastic process and thetheory of rigid and plastic finite element forming theory, introduced several typical processmodes of extrusion and process schemes of spur gears in brief, researched the processtechnology of forward extrusion emphatically. In order to research the influences to theforming process and the mode load by the six process parameters the teeth number, themodule, the fillet radius of teeth root, the blank diameter, re-entrant of mold and theextrusion speed, this paper designed25perpendicular trials of six factors and five levelswhich instead of56=15625trials in a large part.To the simulate test results，the paper extracted the equivalent strain field, theequivalent stress field, the speed field and the stroke-load curve in the process of analysis.With the solution of data, the article took the methods of intuition analysis, effective curvegraphics, analysis of variance and interaction. It got the influences to the forming qualityand mould load which came from the each parameter. The results indicate that re-entrant ofmold and the blank diameter are the most important parameters which influences the unitload press and the precision. The other parameters make few influences on them.Meanwhile the unit pressure of the mould can reflect the used life of molds, and the moulddecides the gear’s quality. The best parameters can be got from the simulations. Thesimulations under the best conditions improve that the results of perpendicular tests arereasonable and right. It provides technology support for process optimization and modeldesign optimization.In order to prove the reliability and scientificity of the simulated experiments, Thispaper just chosen a sample to give the tests as the streamlined, the microstructure, hardness, grain, the size on it and compared with the simulation results. They fit well.