楔横轧齿轮轴轴齿一体化成形机理研究

A study on the integrated forming mechanism of cross-wedge rolling gear shaft and tooth

为实现齿轮轴短流程高效精确制造,本文创新了楔横轧齿轮轴一体化成形方法。在分析齿形塑性成形原理基础上,综合出加工模具的主要参数,得出了满足分齿条件的参数公式,设计出齿轮轴楔横轧模具;通过Deform软件对齿形模具进入加工过程的阶段进行了仿真,得到齿形模具于阶梯轴第1阶段展宽段进入加工成品质量最佳。在此基础上进行仿真,分析其应力场、应变场以及温度场,进而阐明齿轴一体化楔横轧成形机理。仿真与实验结果比较表明:误差在8.2%以下,验证了仿真结果的可靠性。本文研究结果为实现齿轴一体化精确短流程成形奠定了理论基础。

To realize high-efficiency and accurate manufacturing of gear shafts in a short process,this paper pres-ents an innovative integrated forming method of cross-wedge rolling gear shafts.Based on an analysis of the princi-ple of tooth profile plastic forming,the main parameters of the processing die were synthesized,obtaining a parame-ter formula satisfying the condition of tooth separation and the design of the gear shaft cross-wedge rolling die.The stage of the tooth mold entering the machining process was designed using the software Deform,obtaining the best quality of the tooth mold entering the finished product in the first stage of the stepped shaft.On this basis,the sim-ulation was conducted to analyze the stress field,strain field,and temperature field.Then,the forming mechanism of gear-shaft-integrated cross-wedge rolling was clarified.A comparison of simulation and experimental results showed that the error was less than 8.2%,verifying the reliability of the simulation results.The results of this pa-per lay a theoretical foundation for the realization of the precise short process forming of gear shaft integration.