The Study Of Forming Process With Numerical Simulation Of Driven Spiral Bevel Gear Blank In Automobile Rear Axie Main Reducer

The spiral bevel driven gear is one of the important parts of Automobile Rear Axle main reducer, it plays an important role of bearing load in the automotive transmission process. As the automobile production increases, the demand of spiral bevel gear is also increasing year by year. The blank of spiral bevel driven gear requests high quality, low cost in materials and energy when produced in a large scale. Therefore, optimizing the blank forming process, improving quality and reducing cost and noise have become an important research trend in automotive industry.The main research content of this paper is as follows:Firstly, the comparative analysis with the various forming processes of gear blank is performed, and the best forming progress that is suitable for this paper is found.Secondly, the size of blank, forming die and equipment selection are calculated respectively in closed die forging, single ring rolling process and double ring rolling process. The forming processing plan of spiral bevel gear blank is confirmed by comprehensive comparison.Thirdly, various forming progresses are verified and optimized by the finite element numerical simulation software DEFORM-3D, and confirm the optimized shape and size of the prefab blank in the progress of ring rolling.Finally, on the basis of the study of single ring rolling process, the forming process of double ring rolling is analyzed and optimized.In this paper, two kinds of forming progresses are compared,closed die forging process and ring rolling process.and the material utilization.is calculated respectively By comparing the result, the material utilization in ring rolling process is higher than that in closed die forging progress. Then by comparing the equipment and energy consumption in two progresses, finally selected the ring rolling forming technology as the optimal progress plan to form the gear blank.On the basis of the study of single ring rolling process, the forming process of double ring rolling is simulated. By the analysis of the forming process of stress and strain distribution, geometrical configurations and forming size, it is indicated that the stress distribution of double ring rolling process is similar with that of single ring rolling process, and its geometrical configurations and forming dimensions meet the demand. Through the comparative analysis of the blank utilization of single ring rolling process and double ring rolling, the blank utilization of double ring rolling is increased, which lead to productivity improvement and cost reduction. This process provides an important theoretical basis for future practice.