Optimization Of Process Parameters For Local Loading Hot Forming Of Large Gear

Gear is one of the typical mechanical transmission components and is widely used in aerospace,automotive,machinery,metallurgy and other industries.With the rapid development of China's industry,gears play an irreplaceable role in other mechanical parts.In the actual production of gears,plastic forming methods are increasingly being valued by people.However,the gears produced by the plastic forming method not only have too large forming load,but also have high requirements on processing equipment.Processing a gear with a diameter of more than one meter often requires tens of thousands of tons of hydraulic equipment,which cannot be applied to the processing of large gears.on.In this paper,a large-sized gear with a modulus of 20,a number of teeth of 60 and a diameter of more than one meter is the main research object,and a new method of partial loading thermoforming of large gears is designed.The forming process utilizes the principle of electromagnetic induction heating to locally heat the cylindrical blank,so that the initial forging temperature of the blank reaches a desired temperature,and then is placed on the top piece to maintain the same moving direction with the punch,and the blank is pressed into the concave mold cavity.among.Due to the joint action of the punch and the concave mold cavity,the outermost layer of the blank is plastically deformed,and the gear tooth shape is gradually formed in this process.Since the inside of the blank is a rigid region,deformation does not occur.In this paper,the partial loading thermal numerical simulation is carried out with two teeth of a large gear with a modulus of 20 and a number of teeth of 60.The metal flow law and load stroke curve during the forming process are analyzed by DEFORM-3D finite element software.In addition,the ingot forging temperature T,the pre-heating temperature t of the mold,the friction coefficient ? between the blank and the mold,the pressing speed V of the punch and the arc length L of the forming section of the die are also analyzed.The influence of mass and forming load,and finally a set of optimal process parameters.