Research On Casting And Ring Rolling Forming Process With Numerical Simulation Of Driven Spiral Bevel Gear Blank In Automobile

With the rapid expansion of China’s automotive industry, the demand of automotive main reducer driven spiral bevel gear which is vital in transmission parts is increasing.In addition, the quality requirement have become more strict.The conventional manufacturing technology of driven spiral bevel gear blank is hot die forging and rotary forging.However, die life must be higher to those two process.So,the corresponding cost of production also increased.Beside, those two process only apply to the production of small ring gear blank.This paper adopts the composite forming process of casting and ring rolling to form driven spiral bevel gear blank.Ring rolling which also know as rotating precision forming is a partial load continuous forming process.This forming process could reduce size of the machine and cost of production.Moreover, it not only optimize the organization and performance,but also heal and repair casting defects.This paper adopts sand casting to produce blank. It is beneficial to avoid the low utilization rate of material by conventional manufacturing technology, shorten the process line,reduce the energy consumption and emissions.Therefore, research on casting and ring rolling forming process of driven spiral bevel gear blank has a high practical value.Object of this research is driven spiral bevel gear blank in a certain type of car.First, according to part drawing design ring rolling forming technology program reversely and using DEFORM-3D software for simulating forming process.Through numerical simulation we demonstrate the feasibility and superiority of program.In addition, we analyze the rule of deformation, heat transfer and evolution of the microstructure in ring rolling process.When the taper of driven spiral bevel gear blank is different, the gear blank in contact with the mold in different ways.Therefore,taperof gear blank deeply effect ring rolling forming process. This paper analyze different taper of gear blank effect on forming force, stress and strain fields,the metal flow pattern, temperature and evolution of the microstructure.In this way, the best taper of driven spiral bevel gear blank was determined.After comparing various casting methods according to the material and construction features of driven spiral bevel gear blank, the scale of production and cost, this paper chose sand casting process.Lateral cut casting plan and center top cut casting plan was designed.Anycasting software was adopted to analyze the filling,solidification process and casting defects of the cast part.According to the simulation result determined the best casting plan.The distribution of casting defects and residual air with different casting temperature and casting speed confirmed the best technology parameter to obtain the best quality of casting driven spiral bevel gear blank.