Straight Bevel Gear Vibration Orbital Forming Technology

Rotary forging is a technology that applied in partly presswork succession plasticity forming. Although it has the notable advantage such as low forming force, workpiece have high quality surface compare with the conventional forging method, it still has some problem. Because of the partly and continuously depresses are being put on the workpiece through the whole forming process, the load condition of the workpiece is not even, this will lead to defective workmanship such as waste product of pulley shape and verse and inverse mushroom shape. To avoid such drawbacks, a longitudinal simple harmonic vibration is put on the Moulds - workpiece system in Rotary forging which is called Vibrational Rotary forging. The deformation resistance of the workpiece reduced and the overall forming become more uniform during the vibration forming process, thus avoid the process of waste in producing, workpiece also have batter forming quality. So the new Vibrational Rotary forging method have wider application foreground.The forming process of Straight Tooth Cone Gears under Vibrational Rotary forging is researched by combining theoretical analysis and computer simulation, the main works as done as follow:(1) How the kinematics of die affect the load condition and the factors which affect the forming quality of workpiece are researched under the analysis of forming principle of Vibrational Rotary forging.(2) By using the theory of Space geometry, the Analytical equations of Spherical Involute and other Structural curve of the Straight Tooth Cone Gears is established under the forming principle of the gear's tooth profile surface. The Straight Tooth Cone Gears were parametric designed accurately in environment of Pro/Engineer, which provide the basis for the design of this kind of gear and its finite element simulation.(3) Combined with the rigid-plastic finite element theory, the forming process of gear under different method was simulated in software DEFORM-3D through the establishment of related physical model and the designed simulation experiment scheme. Compared to Rotary forging the deformation resistance of the gear during forming process reduced and the forming quality become better in vibration.(4) According to the simulation of the gear's forming process under different vibration model parameters and its different combination, it shows that the vibration model parameters must be reasonable selection to obtain better forming quality.(5) The service life of die is closely related with the chosen Process parameters during Vibrational Rotary forging. The Fatigue damage of die always occurs in the position of the gear's addendum and dedendum. All mentioned above shows that the research of this dissertation will provide some available approaches for the High-efficient precise forming of the Straight Tooth Cone Gears, and has better applicable value.