The Forging Dies Design and Wear Analysis of Straight Bevel Gear

摘要

In the straight bevel gear forging process, the amount of wear and its distribution locations in die directly affect the motion performances of gear sets. The objective of this study was to design a new type pre-formed die of straight bevel gear to decrease the amount of wear for increasing life of die. The Archard's wear model within rigid-thermo-viscoplastic finite element analysis software was used to predict the amount of wear, the distribution locations, and life of the dies. Two-stage forming process was developed in this study. A new pre-formed tooth die (NPFTD) divided the metal in earlier forming stage while the metal flowing in the cavity. Finally, a final-form tooth die was used to complete the expansion of the gear tooth. A cold extrusion experiment was used to validate the forming load of the simulation model. From this study, it was observed that the two-stage forging process with NPFTD will provide 19 times productivity compares with the traditional forging process.