The Whole Manufacturing Process Simulation Analysis Of Driven Spiral Bevel Gear Blank And Research On Mold Life

Driven spiral bevel gear is an important component of automobile axle,recently,with the prosperity of the automotive industry,the demand for driven spiral bevel gear blank has been increasing.Compared to the traditional forging production process of gear blank,the large ring rolling production process has several advantages,including smaller equipment tonnage,better working environment,higher material utilization and higher productivity.Wear failure and fatigue failure are two main forms of forging die failure for driven spiral bevel gear blank.Since forging molds bear a complex stress during the forming process,researches of failure mechanisms and reasons lack depth and meticulousness presently.Based on the Deform simulation platform,the whole manufacturing process of the driven spiral bevel gear blank was studied,particularly the ring rolling process.It is important to improve production efficiency and shorten the process design cycle of ring components similar to gear blank,it also can reduce the labor intensity of designers and improve the design efficiency and production capacity further.Failure factors of hot forging die are worth considering to extend die life.In the paper,the ring rolling manufacturing process of driven spiral bevel gear blank is firstly metal bar sawing,then induction furnace heating,then upsetting and punching under air hammer,then ring rolling,lastly die forging.Three-dimensional finite element software Deform-3d was applied to simulate the whole process of driven spiral bevel gear blank,the simulation results showed a good forming quality without bad defects,which can provide a reference for process design and mold design of the same ring components.Ring rolling is an important step during the whole production process,the influence of the preform height on ring rolling quality and enegy consumption was also studied,the results showed that the lower the preform height,the less the overall energy,the smaller the ring pit defects.Aiming at the wear failure of closed forging die,the orthogonal experiment method was used to study the influence factor of forging die wear,which includes the mold hardness,forging speed,the mold preheat temperature and the initial temperature of the billet.On this basis,range analysis and variance analysis were made to optimize mold forming load and the amount of wear,the process got the optimum molding parameters and the mold wear life were estimated and validated.It proved that simulation results are consistent with the actual life of hot forging die in factories.Aiming at the fatigue failure of closed forging die,the elastoplastic finite element model was used to analyze stress distribution of closed forging die,simulation results showed that stress concentration is serious,the maximum equivalent stress peak is in the vicinity of small mold corners,it leads to fatigue failure of the mold small corners easily.Since simulation results were consistent with the actual production,simulation results indicated reliable.Different shape parameters and forming parameters were used to simulate their effects on the mold temperature field and the stress field.On this basis,local stress fatigue life estimation model was used to calculate the fatigue life of the mold.Mold FEM analysis and life estimation model were combined to make the die fatigue life estimation reliable.Estimate results can judge the merits of mold design qualitatively,provide references for the mold development and enterprise production.