Research On The Production Technology And Equipment For Manufacturing Gear Blank By The Round Bar

The ring gears are indispensable parts,which widely used in construction machinery,automobile and other fields,such as the slewing ring of hanging car,engine flywheel ring gear and so on.As the application fields are very extensively,under the premise of guaranteeing quality,how to reduce the production cost,improve the production efficiency have become a urgent problem to study and solve.For the process of hobbing is basically the same,so,in this paper will do some in-depth research on the process of gear ring manufacture,matching equipment and production process to meet the requirement of industry development.In order to improve the material utilization and production efficiency,a new blocking technology was put forward in this paper.According to the requirements of the production process,forming the butt welding ring just by one-off rolling,the new three-roller rolling machine and five-roller rolling machine were designed in this paper,that solved these problem well in the production process,such as:poor rolling efficiency,cumbersome rolling process step and the remained straight edge shaped as trumpet.On the basis of rounding rules,this paper established the mathematical relationship between the roller position and rounding radius.The rolling process was simulated by using ANSYS/LS-DYNA software,obtained the changing principle of the blank's internal stress and shape when in rolling process.For getting more reasonable wheel arrangement,the structure of five-roller rolling machine was optimized by using APDL language.A three-roller rolling machine was trial-produced,via comparing with the theoretical results verified the practicability of the machine with the production test.In order to get the rectangular cross section of ring gear blank,this paper has been made the die forging process route according to the ring gear blank parts characteristics;calculated the blank volume and the forming force;designed the forging draft,blank shape,die and overall mold set;drawn the mold assembly diagram.The forging process was numerically simulated by DFFORM-3D;and analyzed the process parameter impact on forming process,such as friction coefficient,forging temperature and forging speed.Through analyzing relevant field,to get the ring gear blank forming law and appropriate process parameter for production,have provided an important theoretical basis for practical production.