倒挡齿轮冷锻成形有限元模拟

Finite Element Simulation on Cold Forging Process of Back Gear

简述倒挡齿轮的冷锻成形工艺,即先采用分流锻造工艺预锻出齿形,再精整齿部倒锥。根据倒挡齿轮预锻工艺方案建立弹塑性-弹性耦合三维模型,采用弹塑性大变形有限元法仿真倒挡齿轮的锻造过程,并结合物理实验中坐标网格变形图分析倒挡齿轮成形过程中的金属流动规律。基于位移场信息计算由弹性变形引起的尺寸偏差,并与实测结果对比,两者沿齿形的分布趋势一致,且可以观察到变形后的齿形曲线具有非渐开线特征。预锻成形中的弹性变形定量预测可为后续的齿部精整工艺及模具设计提供参考依据。

The cold forging process of back gear was briefly introduced. The back gear is preformed by divided-flow method, and back taper of tooth is formed by final finishing. Elastic plastic-elastic 3D coupled model was created based on preforging scheme and the forging process of back gear was simulated by FEM, and the metal flow rules were discussed by investigating coordinate grid deformation results in physical experiments. According to the displacement field information the dimensional discrepancy caused by elastic deformation behavior was calculated. The calculate results are close to the measured values, and the profile of gear tooth after deformation has non-involute feature. Quantitative estimation of elastic deformation after preforging provides a reference for the process and die design of the final finishing.