主动螺旋伞齿轮闭塞模锻物理模拟

Physical simulation of no-flash die forging of spiral bevel driving gear

根据金属流动趋势设计了主动螺旋伞齿轮的预制坯;开式模锻螺旋伞齿轮试验结果显示,模具结构复杂,所产锻件有飞边;采用闭塞模锻成形了螺旋伞齿轮铅试件,揭示了闭塞模锻主动螺旋伞齿轮成形过程,说明了用闭塞模锻工艺成形主动螺旋伞齿轮的可行性;通过铅试件网格试验,揭示出在闭塞模锻中金属内部质点的流动规律、金属流线分布趋势及纤维状况,说明了锻造齿轮内在质量高的原因;提出采用局部加热,以工件柄部代替大端冲头,设计大、小端双动冲头闭塞模锻模具的创意.研究结果表明,螺旋伞齿轮闭塞模锻铅试样物理模拟对该类零件精密成形工艺制定及模具设计具有重要指导意义.

According to the metal flow trend in forging process of spiral bevel driving gear, the preformed blank and die have been designed and manufactured. Open-die forging test of lead work-piece showed die structure being complex and flash being created. No-flash die forging tests disclosed the filling procedureand the feasibility of process for spiral bevel driving gear. The metal flowing pattern and the tooth filling process at different sections have been described by using network test. Through flow line distribution and fiber contexture of inner material point obtained from no-flash die forging test, the forged gears with high quality grade was explained. On the basis of the results, a new die structure of no-flash die forging for spiral bevel gear with local heating and double acting die has been claimed. The finding declared that physical simulation of no-flash die forging for spiral bevel driving gear with lead work-piece can be used for the design of process and die structure of precision plastic deformation of such part.