The Research Of 500 Roll Forging Machine And Process

As a mass produced key part in the car, the driving gears are applied into the driving of cars and closely related with the safety of cars’ moving. It’s very important to enhance its forging quality and materials utilization through the optimization of forging production process. The forging of driving gear is commonly produced by using air hammer, but the process has many disadvantages: such as large noise, high demand of factory building and foundation etc. Using Orthogonal experimental method and finite element analysis method, this paper designs the multi-channel time roll forging die, sums up die design method, and optimizes roll forging process and die structure parameters. The 500 roll forging machine is designed out successfully by adopting the analogy method. The main works are as follows:(1) This paper analyzes the roll forging deformation rule and technological characteristics, designs the roll forging moulds for forgings with different diameters. For the phenomenon of flash and fill, we conduct the slot and the slope test. Finally we can get the slot section sizes with good roll forging effect, and the suitable Angle. After we complete five different diameter roll forgings die design, we discuss the effect of different slot cross-section, different slopes and different processing parameters on the quality of roll forgings, then we summarizes the design method. At the same time for Φ55 roll forging, we conduct five factors of two levels orthogonal test. We take the die Angle, friction factor, the billet temperature, mold temperature and the initial hardness of mold as five factors, the maximum forming load and mould wear as two major indicators. After we compare the effect of each parameter on the forming process and quality of product, we can obtain the optimal parameter combination. The test under the optimum parameters proves the two indexes reach the minimum.(2) By analyzing the working principle and performance characteristics of roll forging machine. We design 500 roll forging machine on the basis of the 360 roll forging machine. We modify some structure, replace bearing shell with rolling bearings, and make the slider into a whole. We complete the virtual assembly and interference analysis, and the machine can be applied to production. Also we conduct finite element analysis for 500 roll forging machine. The statics analysis shows that the stress value is in the range of allowable stress, displacement is also in the range of requirements; modal analysis shows that roll forging machine will not occur resonance phenomenon; the stiffness and first order modal of roll forging machine topology optimization, can provide the basis to improve the size and structure of the weak positions.