Transactions of Materials and Heat Treatment

Title：Numerical simulation on a new precision forming of helical cylindrical gear with one step

Authors： Chen Jia Zhang Ruhua Zheng Zhiqiang Long Qibo Chen Fanhui

Unit： Nanchang University

KeyWords：

ClassificationCode：TG316

year,vol(issue):pagenumber：2016,41(9):13-17

Abstract：

It was studied the one-step forming method of helical cylindrical gear which combined the

advantages from the divided forming and the push sizing. For the helical gear with modulus 4

mm, teeth numbers 12, angle of helix 14° and teeth width 29 mm, the structure of die was

designed and the whole forming process was analyzed by Deform-3D numerical simulation

software. Firstly, the forming force was analyzed, and then the influences of structure

parameters of the expanding cavity such as b in tooth width direction, bevel angle α, and h

in tooth height direction on filling effect at the bottom corner and the forming force were

discussed by the method of control variables. The results show that the forming load of the

new method is obviously reduced. Thus, the forming effect dependent on the amount of divided

metal, which is controlled a combination of b，α and h. However, the effects of their changes

are similar. When other conditions are kept fixed, a smaller b (or α, or h) brings a larger

forming force with insufficient differential throttling resulted in inadequate corner fulling.

On the contrary, even though the forming force is small to form teeth completely, the divided

metal is overmuch to produce the waste. Only a suitable combination with b 16 mm,α 10° and h

3 mm is acceptable. In conclusion with suitable divided metal and reasonable forming force, a

fulfilled corner gear without waste can be obtained.

Funds：

江西省教育厅科技计划项目（GJJ13192）；江西省发明专利研发引导项目（20143BBM26105）

陈家（1990-），男，硕士研究生

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