Study on precision forming and lift-out process of small cone angle spiral bevel gear by finite element analysis

摘要

Meshing tooth surface of a small cone angle spiral bevel gear appears as the spiral structures. And the cone angle pitch is small, while helix angle is large. It is very difficult for materials to precisely flow into the cavity in precision-forming process. It is also difficult to ensure that no damage is introduced in the forging rotated from the gear cavity. Deform-3D analysis shows that material deformation primarily occurs on the tooth part in the forging process. On the tooth profile, the flow of material is primarily radial direction. In the gear root area, the flow of material is the radial direction and axial compression. In the center of the tooth profile, the flow of material is primarily vertical. ADMS analysis of liftout process indicates that the spiral bevel gear can be put out of the cavity smoothly. With an increase of the pressure angle, the liftout force decreases. With an increase of the spiral angle and tooth width, the liftout force increases. Finally, spiral bevel gear Pb sample is obtained by precision plastic forming technology. It is proved that the spiral bevel gear can be manufactured by precision plastic forming technology and the numerical result is reliable.