Manufacturing Technology 2023, 23(6):958-966 | DOI: 10.21062/mft.2023.102

Precision Forming Process Analysis and Forming Process Simulation of Integrated Structural Gear for New Energy Vehicles

Liyong Zhang ORCID...1, Tianle Zheng ORCID...1, Tongjie Li ORCID...1, Juan Wang ORCID...1, Changlu Wang ORCID...2, Yehu Jiang ORCID...3, Chengyu Li ORCID...3, Fengxia Yuan ORCID...1, Zhihua Yao ORCID...1
1 Anhui University of Science and Technology Chuzhou 233100 China
2 Jiangsu Zhonggong High end Equipment Research Institute Co., Ltd. Taizhou 225300 China
3 Anhui Zhongxin Technology Co., Ltd. Chuzhou 233100 China

New energy vehicles driven by electric motors have higher requirements for the lightweight and high reliability of their gear transmission devices. It is now necessary to optimize the precision forming process of their structural gears. The integrated structure gear without undercut produced by precision forming technology can reduce axial size while improving the strength and reliability of gear parts. Based on the performance requirements of integrated structural gear parts in practical applications, a process plan of "hot forging forming +cold trimming tooth shape" was developed, and compared with existing hot extrusion forming plans. Simulation analysis was conducted on the hot forging forming process of integrated structural gears. Through the improvement and optimization of the process plan, the extrusion stress during the filling process of the formed gear teeth was reduced by about 29%, achieving a good forming effect, in order to provide data reference for the forming of this type of gear.

Keywords: Gear forming, Precision forming, Cold extrusion, Simulation analysis, Extrusion stress
Grants and funding:

This project is funded by the following projects: Anhui Provincial Science and Technology Department Key R&D Project (2022a05020063); Tianchang Intelligent Research Institute Project (tzy202101); Anhui Provincial Department of Economic and Information Technology Agricultural Machinery Shortcomings Project (No.JB23802); Anhui University of Science and Technology Support Project (RCYJ201904) and Fengyang County Science and Technology Project (No. 2023TPY05)

Received: September 24, 2023; Revised: October 24, 2023; Accepted: November 30, 2023; Prepublished online: December 7, 2023; Published: December 22, 2023  Show citation

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Zhang L, Zheng T, Li T, Wang J, Wang C, Jiang Y, et al.. Precision Forming Process Analysis and Forming Process Simulation of Integrated Structural Gear for New Energy Vehicles. Manufacturing Technology. 2023;23(6):958-966. doi: 10.21062/mft.2023.102.
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