Research And Development On Precision Forging Process And Mold For Vehicle Differential Bevel Gear

Using precision forging process to produce bevel gears, the cost is reduced and the efficiency is enhanced. At the same time, the abilities of anti-erode, anti-wear, anti-bending and anti-fatigue of gear are improved. With the rapid development of automobile industry and increasing competition in the market, the quality of bevel gear needs to be improved. So improving process design and mold structure, which can improve the forging quality, production efficiency and reduce costs, becomes the inevitable development trend.This paper mainly makes improvements to the problem of large flash on forgings in original open-die forging technology for automobile differential planet bevel gear in enterprise, which can make forgings without larger horizontal flash and improve the quality and precision of forgings. It not only can improve material utilization and production efficiency, but also can make improvement on the mechanical properties of the gear and increase market competitiveness, due to reducing machining.In this paper, firstly, according to the principle of closed-die forging, making the process and mold of original open-die forging for vehicle differential gear improved, through determining the reasonable process parameters and designing the relevant mold structure, realizing closed-die forging in friction screw press. In the process of technology and mold research and development, modeling the bevel gear part and mold by using UG software, using DEFORM-3D software for forging simulation analysis. By analyzing the velocity field, strain, stress, forming load and filling ability, determining the optimal process parameters and making the mold structure design more reasonable. Then, combining the law of bevel gear forming, discussing the main failure forms of mold, checking whether the mold meet strength requirement or not, by analyzing the stress of mold cavity. Finally, formulating reasonable methods for processing mold to ensure the precision and increase service life of mold.