However, up until now, no in-depth research has been conducted on the method for calculation of mold release interference. Lai was focused on the forging process and simulated it with a numerical method Gao investigated the gear tooth forming control in the closed die hot forging of spiral bevel gear.Īltogether these recent works exhibit the great industrial reliability and prospect of spiral bevel gear forging technology. carried out a comprehensive study of spiral bevel gear forging, including both the pinion and the gear, from mold design to forging process and to the final product test. And for a long time, spiral bevel gear forging technology did not witness much progress, which can be ascribed to two factors as follows: (1) failure to manufacture the mold (2) failure to calculate the mold release interference.ĭuring the last decade, along with the development of multi-axial machine tool and rotary EDM (electric discharge machine) tool, mold manufacture becomes no longer a problem. , yet, with the failure of mold fabrication for the pinion, their work was only focused on the wheel. synthesized the design and hot forging processing for noncircular spur bevel gear with asymmetrical geometry.įollowing the great advantages of spur bevel gear forging in practice, researches have been carried out on generalization of the method to spiral bevel gear, which bears resemblance to spur bevel gear in geometry. simulated the hot precision forging process of straight bevel gear using finite volume (FV) method Samołyk investigated the cold orbital forging process of an AlMgSi alloy bevel gear Zhuang et al. carried out numerical and experimental investigation of cold rotary forging of a 20CrMnTi alloy spur bevel gear Khalilpourazary et al. discussed the problem of producing bevel gears in a single operation by the complex forging of structural steel on a press with reversibly rotating die (the KOBO method) Song and Im investigated the process design for closed-die forging of bevel gear by finite element analysis Gronostajski and Hawryluk gave a review of the main aspects for precision forging of spur bevel gears Liu and Cui discussed the hot forging process design and the parameter determination of magnesium alloy AZ31B spur bevel gear Deng et al. proposed a die design method for bevel gear forging to both improve the product quality and secure the effective material based on the 3D FEM analysis Bochniak et al. simulated the precision forging of bevel gears using implicit and explicit FE techniques Birker and Pedersen studied the contact problem and cyclic plasticity in high-pressure tools by use of non-linear FE analysis Lee et al. established the numerical and physical model of cold forging for bevel gears Doege and Nägele investigated the precision forging process of bevel gears Fu and Shang discussed the optimal design of the forging die for a bevel gear by analysis of the stress Mamalis et al. Currently, forging has become the dominant processing method for the bevel gear in mass production and many works are focused on its design, simulation and optimization: In the traditional method of cutting, gear parts are obtained through removing materials from the blank, while in the relatively advanced forging method, gear parts are obtained through filling materials in the mold, –9] Following strength improvement, material reduction and cost saving, the forming method in gear industry has been well developed, –12]. Many processing methods of gear parts have been developed and the majority of them can be categorized into cutting and forming methods, –6]. Gear, as one of the key parts of mechanical systems, is widely used in power transmission for mechanical devices, –3]. Subsequently, based on the method, a computerized program is developed, in which the ideal mold release motion can be obtained through adjusting the recommended motion according to the mold release interference analysis. To resolve this, this paper, through deriving the equation of the tooth surface, investigating algorithm for mold release motion interference and discussing the motion parameter presetting, proposes first a mold release motion analysis (MRMA) method for forging spiral bevel gear. Accurate design of mold release motion (MRM) to avoid interference, however, remains a problem due to the fact that the tooth lengthwise of spiral bevel gear is not straight. The major hindrance originally lied in the manufacture of the mold, and along with the development of multi-axial machine tool, it is now no longer a problem. Spiral bevel gears, meanwhile, are widely generated by machining, including face-milling, face-hobbing, etc., in spite of the superiority identified of forged spiral bevel gears for years. At present, spur bevel gears are mainly processed by forging, showing advantages of high processing efficiency, low processing cost and fine microstructure material.
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