Research On The Tooth Modification And Forging Process Of The Straight Bevel Gear

Along with the application of forging in the field of Gear Manufacturing,the differential gears of vehicle are mainly produced by forging method.The meshing performance of gear is influenced by tooth shape,forging process parameters,die structure.This paper focuses on a foring bevel gear product,which have problems of offset loading and low accuracy.Based on this problem,this paper discusses the gear modification and the hot forging process of gear,the main research is as follows:Considering the problems of this product as well as the common defects of broken teeth,noise and vibration,this paper eatablishes meshing performance evaluating system:transmission error?35?_max,maximum bending stress?_?max,contact pattern evaluation coefficient?.Research on modification parameters'effects on meshing performance with the composite use of Single-Factor Experiment,Full factorial Design,Response Surface Analysis Methodology.The optimal modification parameters are:profile crowning C_?=30?m,eccentric crowning C_c=50?m,factor f₁=0.4,factor f₂=1.2.Carry out the infinite simulation of gear hot forging process using the DEFORM,and research on the influence of billet dimension and die structure to Metal filling,damage factor,Metal flowing,load.The optimum technological parameters are as fllows:billet dimension?48×77.4mm,upper boss t₁=8mm,lower boss height t₂=6mm.Analyze the elastic-deformance of die and forging during the process,and design the inverse-compension of die cavity based on the deviation of forging.Finaly,the simulation result shows that the forging dimension can meet the precision requirements.With the forging experiment of pinion gear,the experimental result fits well with the simulation result.The contact pattern results can meet the GB 8 accuracy.With the use of software DEFORM,KISSsoft and ANSYS,this article researches the whole design processes of product modeling,gear modification,hot foring,inverse-compension of die cavity.The study solves the problems encountered in the company,which can be used for reference in other forging processes.