基于分流法的圆柱直齿轮冷精锻成形工艺研究

Cold precision forging technology of spur gear based on divided flow method

针对圆柱直齿轮冷锻的载荷大、充填性能差等技术难题,提出了齿顶分流工艺和上齿端分流工艺。结合浮动凹模技术,采用数值模拟与物理试验相结合的方法,对2种工艺进行分析研究。结果表明:上齿端分流工艺不能有效地改善齿形棱线部位的充填性能,而且载荷降幅不大,不能完全避免充填最后阶段载荷的急剧上升;齿顶分流工艺不仅可以有效地改善角隅棱线部位的充填性能,而且载荷得到了极大的降低,完全避免了载荷曲线的急剧上升。

Aiming at the technical problems of cold forming process of spur gear such as excessive forming force and insufficient corner filling,two divided flow methods-one with its divided flow cavity on the top of tooth and the other on the end plane of the gearare put forward.Combining with floating die system,these processes are analyzed by the method of numerical simulation followed by physical experiments.The results show that the process with divided flow cavity on the end plane of the gear is not effective on decreasing the forging load and improving the corner filling,and there is still a steep rise at the end of load curve;while the process with divided flow cavity on the top of tooth is in favor of improvement of the corner filling condition and decreases the forming force significantly,and there is no sharp rise at the end of load curve.