Abstract
This paper took the lead in applying isothermal forging technology to form a spur bevel gear in a single operation. According to the isothermal forging process, the forging part drawing of the spur bevel gear was defined. The 20CrMnTi was chosen as the gear materials. A closed-die structure was used in the forging process. Then, the model of the dies and workpiece were built by UG software. After the models was imported into DEFORM-3D, the simulation of the isothermal forging process of the bevel gear was executed. Through simulation, the shape of the gear, the distributions of effective stress and strain, the forming load of the dies, the laws of metal flow and the filling of the metal during the forging process were gained and thoroughly discussed. The results revealed that the full forging process can be divided into four periods and precision spur bevel gear can be obtained without causing under-filling and folding defect by using the isothermal forging with closed-die forging structure, which provides guidance to manufacturing the spur bevel gear.
Highlights
Straight tooth bevel gears have been widely applied in automobile, agricultural machinery, engineering machinery, etc
1,Resistance of deformation is so large that it is necessary to carry out intermediate heat treatment and superficial treatment in the cold forging process; 2,It is easy to result in the reduction of accurate dimension and surface quality due to the strong oxidation in hot forging; 3, warm forging overcomes the drawback of cold forging and hot forging, requirement for equipment is higher
Few researchers have carried out investigation on applying isothermal forging to form spur bevel gears because it is difficult to ensure the die and billet to remaining high deformation temperature for a long time and the die trend to soften under high temperature
Summary
Straight tooth bevel gears have been widely applied in automobile, agricultural machinery, engineering machinery, etc. According to the difference in deformation temperature of billet, the precision forging technology can be divided into hot precision forging, cold precision forging, warm forging and isothermal forging[1]. Few researchers have carried out investigation on applying isothermal forging to form spur bevel gears because it is difficult to ensure the die and billet to remaining high deformation temperature for a long time and the die trend to soften under high temperature. In recent years, with the rapid development of isothermal forging technology of titanium alloy, the heat insulation device and die material[11] can be employed in isothermal forging of gear steel 20CrMnTi. To ensure the precision of the simulation, the mechanical properties under low temperature of 20CrMnti was gained by a series of. The metal flow, forming load and the deforming field valuables during the forging process were obtained
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