Process Of Spur Gear Research Articles

Numerical Study on the Comparison of Deformation Characteristics during the Fine Blanking Process of Spur Gears and Helical Gear

As important transmission components, helical gears have been widely applied to mechanical and automotive fields. The traditional manufacturing process for helical gears is machining, which is time-consuming and result in the high cost of gears. In order to improve the production efficiency and product quality of helical gears, a novel forming process principle for the fine blanking of helical gears was developed. In this study, reliable three-dimensional (3D) rigid-plastic finite element (FE) models of single tooth and complete gears were set up and investigated using the software Deform-3D, the deformation characteristics of fine blanking of spur gears and helical gears were compared. Based on the valid numerical models, variation tendency of different field variables such as damage material flow velocity, and mean stress were obtained, as well as the feature of the tooth section, which provides a better understanding of the deformation mechanism of rotational fine blanking process.

Numerical Simulation Research on Warm Forging Process for Spur Gear with Large Module Based on Floating Die Method

The warm forging process of spur gear with large module using floating die set was studied in the paper. The influence of process parameters such as billet temperature, web position, web thickness, frictional factor on the filling of die cavity and forging load were investigated by finite element method. It was concluded that the corner filling of gear can be improved by using free floating die. The forging load decreased with the increase of billet temperature or the decrease of frictional factor. The best web position for die cavity filling was that the web was located in the middle of the forged part.

Numerical Simulation on Precision Forging Process for Spur-Gear with Large Module

The whole precision forging process of spur-gear with large module (module: 4) including warm forging, cold extrusion and cold sizing is analyzed. By using finite element method, cold sizing step of spur-gear basing on hollow-divided-flow method is simulated, the influenc of hollow diameter on the forging force and material flow is discussed in detail. Futher research shows that appropriate different tooth reduction is benefit to forming tooth profile without mechaning after forging. According to the research, to form such spur gear with module 4 and breadth 59mm studied in this paper, the hollow diameter should be 18mm and the tooth reduction should be 1.2mm. The necessary reference and basis to realize practical precision forging process of spur gear with large module is provided eventually.

Investigation of Precision Forging Process of Spur Gears: Numerical Analysis and Experiments

In this study, the precision forging process of spur gears has been investigated by means of numerical analysis. The effect of some parameters such as teeth number and module on the forming force and specific pressure were presented. The simulation works were performed rigid-plastic finite element method using DEFORM 3D software. In order to validate the estimated numerical results, they were compared with those obtained experimentally during precision forging of spur gear using lead as a model material. Results showed that the optimum number of gear teeth is between 10 to 20, that is because of being the specific pressure in its minimum value. Also the results obtained from analyzing the effective strain distribution showed that the maximum strain is located on the root area of the teeth. The work presented in this paper might be used for basic data in the design of the precision forging process.

Study on the Large Module Spur Gear Cold Forming Process by Means of Numerical Simulation

The cold forging process of large module spur gear with four modules and 59mm breadth is performed by means of numerical simulation method. Two processes to forming such spur gears were compared by the simulation method, one is with the closed-die performing and extrusion in the finish-forging, the other is with divided-flow method in the finish-forging. Especially, the divided-flow method is analyzed in detail. The necessary reference and basis to realize practical cold precision forging process of spur gear with large modulus is provided eventually.

Two step forging process of spur gear based on rigid parallel motion

To improve the forging process of spur gear, the metal flow rule is investigated in detail, and a hypothesis of radial rigid-parallel-motive (RPM) flow mode is given. Based on the RPM mode a novel specific gear forging technology is put forward by introduced upend forging process and constrained divided-flow technique. Firstly, finite element method is used to simulate the upend forging pre-forming and RPM finish forging, and equivalent stress field and load-stroke curve are investigated. Secondly, a corresponding experiment is carried out with pure lead to validate the numerical simulation. Thirdly, the peak value of conventional forging process is also simulated and is used to compare with the novel forging process, and the result shows that the forming force decreases significantly, about 35%. Finally, the effect on forming load of two key process parameters (the height of gear tooth after pre-forming and friction factor) is analyzed, and the superiority of the novel forging process is further proved.