Transactions of Materials and Heat Treatment

Title：Optimization on process parameters of doubleroller rotary forging for spiral bevel gear

Authors： Wang Yingjun Zhu Chundong Gao Yufan Liu Xin

Unit： School of Materials Science and Engineering Wuhan University of Technology Wuhan 430070 China

KeyWords： doubleroller rotary forging spiral bevel gear orthogonal test finite element simulation

ClassificationCode：TG335

year,vol(issue):pagenumber：2019,44(5):47-52

Abstract：

When the spiral bevel gear is rolled rotatably by the double rollers, the process parameters have an important influence on forming effect of spiral bevel gear. Then, the process scheme of doubleroller rotary forging for spiral bevel gear was selected by the orthogonal test method, and the selected orthogonal test was simulated by finite element analysis software DEFORM3D. Furthermore, the simulation analysis data were extracted, and the range analysis was carried out.Finally the best process parameter combination of A3B2C1D2E3 is obtained, that is, the initial temperature of rotary rolling part is 950 ℃, the feeding speed of lower die is 2 mm·s-1, the friction coefficient is 0.2, the revolution speed of double rolls is 75 r·min-1, and the blank thickness is 31.22 mm. The obtained experimental results

are consistent with the results obtained by simulation optimization. 〖JP2〗The simulation and experiment results show that the process scheme has obvious improvement on the three test indexes, namely, the contact area between rotary forging part and die is increased by about 43.9%, the maximum forming load is reduced from 1827 kN to 1358 kN, and the particle size is reduced from 58.2 μm to 33.3 μm.

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