Numerical Simulation And Experimental Research Of Precision Forming On Spur Gear With Axially Driven Container

Spur gears with complicated shapes are important drive parts applied widely in the automobile and mechanical industry. Therefore, high material quality, dimension precision, surface quality and combination mechanical properties should be attended. In this paper, taken the spur-gear's cold forging as the research subject, the forming technology and the numerical simulation of the forming process are studied, which is important to enrich and develop the theory and technique of the cold forging and improve the forming design level of spur-gear parts' cold-and-precise forging.Unsuccessful corner filling and excessive deformation at the final stage of the process are the main limitation of cold closed-die forging of straight spur gear. The friction force is one major factor which affects metal deformation rules, the material flow may be controlled positively by utilizing the frictional force over the billet-container interface so that the billet material flow may be easily into the corners of the die cavity the study situation of spur gear with precision plastic forming in domestic and overseas countries is analyzed in this paper, the technology of cold forging on spur gear with axially driven container, which is based on the previous studies, is put forward according to the character of gear forming.The straight tooth spur gear's model has been created in three-dimensional molding software UG based on its prototype. The models which will be used in DEF0RM-3D have been gotten. They're the foundation of finite element analysis in straight tooth spur gear with axially driven container. The models of finite element analysis used in straight tooth spur gear with axially driven container have been created based on the rigid plasticity finite element theory. The statuses of strain and stress, metal flow rule have been attained based on the three-dimensional simulation software DEF0RM-3D by the use of rigid plasticity finite element analysis. And the deformation rulers have been attained.The effectiveness of this method for enclosed-die forging of spur gear is examined by finite element simulation. The results show that the forming pressure is reduced significantly in enclosed-die forging when the die is moved in oscillation, and the material flow can be controlled by moving the container. The effects of cycles and amplitudes on metal deformation rules have been analyzed by changing different cycles and amplitudes. And the optimal formula of cycle which can reduce pressure obviously is ratiocinated in theory, which is validated by the finite element simulation. The effects of friction on the filling of gear and the required pressure are summarized by the finite element simulation. All these provide basis for future production.The feasibility of technology of forming spur gear with floating die is validated by physical experiments. Compared with fixing die, the technology of floating die can indeed reduce the forming pressure and improve the filling effect of gear. The theory that it can reduce the forming pressure with axially driven die is accurate and credible. Also compared with experiment, it explains that the simulation can reflect the true circs, be credible and that the simulation of cold forging on spur gear with axially driven container is accurate and the analyze is credible.