Three‐dimensional FE modelling simulation of cold rotary forging of spiral bevel gear

Abstract

Owing to the complicated three‐dimensional geometry and tool design, mass production of precision spiral bevel gears using conventional forging technology is impeded by a number of quality issues. Cold rotary forging, an innovative incremental metal forming process, has great potential to make up for the present situation owing to its flexibility and low tool load requirement. In the present study, the feasibility verifying the cold rotary forging process of a spiral bevel gear has been carried out via the finite element (FE) method instead of extensive and expensive ‘trial‐and‐error’ experiments. A three‐dimensional rigid plastic FE model was developed to simulate the cold rotary forging process of a spiral bevel gear from a simple workpiece to a complicated product under the DEFORM‐3D software environment. On the basis of this proposed FE model, the workpiece geometry was optimised in order to obtain the low damage risk and forming load requirement. Subsequently, the distribution and variation laws of different field variables, such as flow velocity and strain, were thoroughly investigated. The results of this research not only revealed the deformation mechanism of cold rotary forging of a spiral bevel gear, but also provided valuable guidelines for further experimental studies.