Abstract
Cold rotary forging is a novel metal forming technology which is widely used to produce the high performance gears. Investigating the microstructure and mechanical property of cold rotary forged gears has a great significance in improving their service performance. In this study, the grain morphology in different regions of the spur bevel gear which is processed by cold rotary forging is presented. And the distribution regulars of the grain deformation and Vickers hardness in the transverse and axial sections of the gear tooth are studied experimentally. A three-dimensional rigid-plastic FE model is developed to simulate the cold rotary forging process of a spur bevel gear under the DEFORM-3D software environment. The variation of effective strain in the spur bevel gear has been investigated so as to explain the distribution regulars of the microstructure and Vickers hardness. The results of this research thoroughly reveal the inhomogeneous deformation mechanisms in cold rotary forging of spur bevel gears and provide valuable guidelines for improving the performance of cold rotary forged spur bevel gears.
Highlights
Spur bevel gears, as an indispensable element for momentumtransfer between intersection axes, have been widely used inmechanical, automotive, marine, aeronautical, and astronauticalindustries owing to their high contact ratio, smooth transmission, excellent carrying capacity, and small noise
From small-end to large-end of the gear tooth, the aspect ratio distribution of the grain becomes more inhomogeneous in the circumferential direction
The inhomogeneous distribution of microstructure, the inhomogeneous deformation of the grain, and inhomogeneous distribution of the Vickers hardness in the gear tooth formed by cold rotary forging are investigated by using experimental and FE simulation method
Summary
As an indispensable element for momentumtransfer between intersection axes, have been widely used inmechanical, automotive, marine, aeronautical, and astronauticalindustries owing to their high contact ratio, smooth transmission, excellent carrying capacity, and small noise. Cold rotary forging, a promising incremental metal forming process, is widely applied for the fabrication of spur bevel gears, due to the low raw material and energy expenses, remarkable increase in dimensional accuracy and surface finish, and considerable improvement in mechanical properties of products. The lower die pushes the workpiece vertically at a constant feed rate V so as to cause it to be subjected to axial compression. Under the action of the oscillation of the upper die and the axial feed of the lower die, the workpiece is pressed repeatedly and the desired shape will be completed perfectly
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