轿车差速器齿轮精密成形的有限元数值模拟

Finite element simulation to gear precision forming of car differential mechanism

采用冷摆辗方法来成形轿车差速器半轴齿轮毛坯。首先分析了齿轮成形的工艺特点,利用三维有限元软件——DEFORM对成形过程进行模拟,得到成形过程的金属流动充填规律以及力学量场分布情况,并通过实验来验证模拟结果,为模具设计和制造提供参考。同时,将先进制造技术——CAM技术应用到模具制造中,加工的电极精度达到4级,进而加工出7级精度的齿轮毛坯。结果表明,采用冷摆辗方法来成形轿车齿轮是可行的。

The blank of car differential bevel gear was formed by cold rotary forging technology. The forming technology property was analyzed firstly, the deformation process with finite element method software——Deform was simulated, and metal flow, filling regularity and distribution of mechanics field were obtained. The simulation results were verified by experiment. Besides that, advanced manufacture method——CAM was used to manufacture mold pole. High precision electrical pole of IT 4 and gear blank of IT7 were obtained. The result proves that it is feasible to form the high precision gear through cold rotary forging.