The Study Of Automobile Rear Axle Active And Driven Bevel Gear Blank Composite Forging

Automobile rear axle main reducer spiral bevel gear are important auto parts that will be in demand and high quality requirements. Forging process is a technology which usually use to form gear blank, using different forming process lead to different results, the quality and cost will be differences, especially the large mass production, the cost gap will becomes more evident. The paper presents one heat two parts composite forging process, verification and optimization of process can be received through finite element numerical simulation analysis.Compared to the existing technology, the new composite forging process has many advantages,such as productivity improved, costs reduced, quality stable and so on.Automobile rear axle driven spiral bevel gears are frequently used in pairs or sets performance and materials are the same, plastic forming is required to ensure the quality of the blank. Traditional molding are made separately, respectively generate process waste materials.There are many disadvantage, such as more equipments, complicated process and high energy consumption and labor costs.Based on the above reasons, it is proposed a new molding process of primary driven spiral bevel gear blank composite, by one blanking, heating, forming the two forging which described above. First, cross wedge rolling technology is used to rolling out the rod of spiral bevel gear blank, and then the closed die forging is used to form the end of spiral bevel gear and drive bevel gear blank.The last, separate the two gear blanks which connected with skin. The method could assure product qualities, reduce energy consumption and improve production efficiency.Through analyzing and studying the results of experiment, confirm the feasibility of the technics, the proposed complex process.The technology could provide parameters for the actual production. Through the simulation, the rules of velocity field deformation area distribution and metal flow have been obtained. The upsetting forming process and law of metal flowing was analyzed for heading，rotary forging and forging.The formation ofrolling and forging is simulated and analyzed with the finite element method (FEM) on theplatform of software DEFORM3D.With the FEM simulation, the strain and stress of eachnode under different deformation stage are analyzed and the common forming law ofcomposite forging is obtained. Finally, a group of optimization parameters can beconsulted by the mould designer.Skillfully combine top block forming step of spiral bevel driving gear to forging.Usea few equipments for blanking,heating,rolling, heading, Pre-forging, finish forging, finishforging. Therefore, the process can improve throughput, and eliminate some waste heat.This paper presents that the composite forging process reduces the cutting kerf,oxidation, and with skin material consumption, greatly improving material utilization,approximately14.4%of the savings in raw material.Thereby,the process can improve throughput, and can eliminate some waste heat. butalso some areas need to improve and perfect such as after rolling step, try to use a rotaryforging process instead of forging process.