工艺参数对杯形内啮合齿轮旋压成形影响的数值模拟研究

Numerical simulation of the influence of the processing parameters on the spin-forming of the inner meshing gear of cups

基于金属塑性变形原理和旋压工艺的特点,提出杯形薄壁内啮合齿轮旋压成形技术,建立了齿轮旋压三维弹塑性有限元模型并进行了数值模拟,分析了齿轮旋压成形中各变形区不同方向应变分布和金属流动规律,定性地分析了主要工艺参数对齿轮旋压成形的影响规律。结果表明,压下量对齿轮成形起关键作用,并对齿根减薄影响大于齿顶增厚的影响,进给比对齿轮成形影响不大,大的旋轮圆角半径有利于齿顶增厚。该项研究为提高生产效率、优化产品质量提供了理论依据,同时也为进一步研究齿轮旋压技术奠定了坚实基础。

Based on the metal plastic forming principle and the characteristic of spinning, a new spinning technology for forming thin-walled inner meshing gear was presented. In the paper, a 3D finite element elastic-plastic model had been used to analysis the spin-forming of the gear. The strain distributions and the metal flowing rules in different directions on the deformation zone during the spinning were analyzed. The influence of principal processing parameters on the formability of the gear spinning was studied qualitatively. The results indicated that the reduction of the blank radius per path plays the principal influence on the gear forming, its effect on the thinning of the root of tooth is more than on the thickening of the tooth addendum; the feed rate plays nearly no influence on the gear forming; large roundness radius of rollers is beneficial to the thickening of the tooth addendum. The results provide theoretical evidence for improving the productivity and the quality of the products, and a sound foundation for the further study on the gear spinning technology.