直齿轮刚性平移两步成形工艺仿真与试验

Simulation and Experimental Study on Two Steps Forming Technology of Spur Gear Based on Rigid Parallel Motion

针对直齿轮冷锻成形困难、工作载荷大和模具寿命低等问题,提出基于刚性平移的直齿轮两步成形工艺,即先成形分度圆以外齿形,后完成整齿成形。首先采用有限元法,对两步成形工艺的冲挤预成形和刚性平移终锻成形过程分别进行了模拟,并提取等效应力场和载荷行程曲线进行分析;再用物理试验对数值模拟结果加以验证;最后与传统工艺方案的模拟结果作对比。研究结果表明,刚性平移预锻齿形设计有利于改善齿轮的充填性,同时使得工作载荷大幅度降低。

There are three main problems in the conventional cold forging process of spur gear： insufficient corner filling; excessive forming force; short life of dies. To avoid these disadvantages, a new forming process, which is the two steps forming technology based on rigid parallel motion, is put forward. Firstly, finite element method is used to simulate the upend forging preformation and rigid parallel motive finish forging process, and equivalent stress field and load-stroke curve are investigated. Secondly, a corresponding experiment is done with pure lead to validate the numerical simulation. Finally, the conventional forging process is also simulated to compare with the new forming process. The results show that the two steps forming process is in favor of improvement of the corner filling condition and decreases the forming force significantly.