Research On Double-divided Flow Forming Method For Spiral Bevel Gear

The spiral bevel gears, which have superior carrying capacity and transmission stability, are widely used in various mechanical fields. At present, spiral bevel gear is mainly machined by the method of cutting. With the development and application of precision forging technology, people pay more and more attention to the precision molding of spiral bevel gear. Compared with the traditional gear processing method, the precision forging technology has some advantage such as high production efficiency, conservation of raw materials, low cost, high strength of parts, good surface quality, which is especially suitable for mass production. Because the tooth-surfaces of spiral bevel gear are an arc,the metal flows is complex during the forming process and it’s difficult to fill the mold cavity,which causes the forming force sharply rises, and the mold is easy to break. Therefore,how to reduce the forming force,ensure the forming quality and improve the life of mold is difficulty in precision forging forming of spiral bevel gears.In this paper, spiral bevel gear of automobile driving axle is as an object of study,based on the structural characteristics of spiral bevel gear,the double divided flow forging process was put forward. Firstly, with the help of finite element analysis software Deform-3D, the precision forming process of spiral bevel gears was simulated. The results show that, the double divided flow forging technology can effectively reduce the forming force, comparing with middle divided flow forging technology. Secondly, by studying the metal forming characteristics under different process parameters, the optimum process parameters were determined. And lastly, based on characteristics of final forging forming, the cold finishing processing plan of tooth profile was put forward. The metal flowing situation、stress-strain distributions and forming force of parts during the forming process were analyzed,and the structure of the tooth profile mould was optimized.Based on the above research results, the mould structure was designed. The test was carried out in universal material testing machine with lead. The results show that the double divided flow forging technology can reduce the forming force notably and the optimized parameters can ensure the quality of tooth filling, save materials and meet the design requirements. The forming mechanism shows in experimental results is also in accord with the numerical simulation results.