To investigate the effects of billet geometry on the cold precision forging process of a helical gear, six different billet geometries were designed utilizing the relief-hole principle. And the influences of the bille...To investigate the effects of billet geometry on the cold precision forging process of a helical gear, six different billet geometries were designed utilizing the relief-hole principle. And the influences of the billet geometry on the forming load and the deformation uniformity were analyzed by three-dimensional （3D） finite element method （FEM） under the commercial software DEFORM 3D. The billet geometry was optimized to meet lower forming load and better deformation uniformity requirement. Deformation mechanism was studied through the distribution of flow velocity field and effective strain field. The forging experiments of the helical gear were successfully performed using lead material as a model material under the same process conditions used in the FE simulations. The results show that the forming load decreases as the diameter of relief-hole do increases, but the effect of do on the deformation uniformity is very complicated. The forming load is lower and the deformation is more uniform when do is 10 mm.展开更多
Forging spur gears are widely used in the driving system of mining machinery and equipment due to their higher strength and dimensional accuracy.For the purpose of precisely calculating the volume of cylindrical spur ...Forging spur gears are widely used in the driving system of mining machinery and equipment due to their higher strength and dimensional accuracy.For the purpose of precisely calculating the volume of cylindrical spur gear billet in cold precision forging,a new theoretical method named average circle method was put forward.With this method,a series of gear billet volumes were calculated.Comparing with the accurate three-dimensional modeling method,the accuracy of average circle method by theoretical calculation was estimated and the maximum relative error of average circle method was less than 1.5%,which was in good agreement with the experimental results.Relative errors of the calculated and the experimental for obtaining the gear billet volumes with reference circle method are larger than those of the average circle method.It shows that average circle method possesses a higher calculation accuracy than reference circle method(traditional method),which should be worth popularizing widely in calculation of spur gear billet volume.展开更多
基金Project(51105287)supported by the National Natural Science Foundation of China
文摘To investigate the effects of billet geometry on the cold precision forging process of a helical gear, six different billet geometries were designed utilizing the relief-hole principle. And the influences of the billet geometry on the forming load and the deformation uniformity were analyzed by three-dimensional （3D） finite element method （FEM） under the commercial software DEFORM 3D. The billet geometry was optimized to meet lower forming load and better deformation uniformity requirement. Deformation mechanism was studied through the distribution of flow velocity field and effective strain field. The forging experiments of the helical gear were successfully performed using lead material as a model material under the same process conditions used in the FE simulations. The results show that the forming load decreases as the diameter of relief-hole do increases, but the effect of do on the deformation uniformity is very complicated. The forming load is lower and the deformation is more uniform when do is 10 mm.
文摘Forging spur gears are widely used in the driving system of mining machinery and equipment due to their higher strength and dimensional accuracy.For the purpose of precisely calculating the volume of cylindrical spur gear billet in cold precision forging,a new theoretical method named average circle method was put forward.With this method,a series of gear billet volumes were calculated.Comparing with the accurate three-dimensional modeling method,the accuracy of average circle method by theoretical calculation was estimated and the maximum relative error of average circle method was less than 1.5%,which was in good agreement with the experimental results.Relative errors of the calculated and the experimental for obtaining the gear billet volumes with reference circle method are larger than those of the average circle method.It shows that average circle method possesses a higher calculation accuracy than reference circle method(traditional method),which should be worth popularizing widely in calculation of spur gear billet volume.
