Numerical Simulation And Experimental Research On Precise Forging Process For Large Module And High Thickness Spur Gear

Planet wheel is widely used in construction machinery industry as the rotating component which transmits motion and force. Planet wheel is a kind of spur gear with large module (m=4) and high thickness (h=60mm), which was never precision forged. In this paper a new concept of forming process for large module spur gear was established that is hot forging, cold extrusion, and cold finish forming. Simulation analysis and experiment research have been preceded for this process concept. The results can provide theoretical instruction to the application of large module spur gear forming.In this paper simulation analysis to each step like hot forging, cold extrusion, and cold finish forming is based on finite element simulation of Deform-3D. To get the optimal hot forging preforming gear profile, infinite preforming continuous forming design concept is applied in the design process of gear profile in hot forging step. After simulation the modified hot forging start temperature is also obtained.By numerical simulation of the cold extrusion process and effect analysis of radial and axial entering angles of mould to gear fill, equivalent stress distribution and forming force, optimal results are 120°and 180°Numerical simulation process parameters are reliable basis of experiment mould design. The process experiment verified the rationality of numerical simulation process concept and finally brought spur gear samples met drawing standard.In this paper the deformation rule for each forming step of spur gear by systemic research and workable forming process is created which is hot forging, cold extrusion, and cold finish forming. This process can get ideal size of forged large module, high thickness spur gear. The research results have significant theoretical meaning for large module, high thickness spur gear precision forging process.