渐开线花键冷滚压精密成形工艺分析及试验研究

Analysis and Experimental Study on the Precision Cold Rolling Process of Involute Spline

花键冷滚压精密成形技术是一种高效、精密、少无切削的先进制造技术,具有成形效率高、节能、节材和零件成形性能好等特点。分析渐开线花键冷滚压精密成形工艺过程及原理,对成形过程的单位平均压力、接触面积、滚压坯料直径、滚压力及滚压力矩等进行求解。对渐开线花键进行冷滚压精密成形试验,分析零件变形区的金属流动规律,组织形成机理及塑性变形对成形性能的影响。试验结果表明,在花键冷滚压精密成形过程中,工件表层发生剧烈的塑性变形,晶粒沿齿廓呈连续的流线型分布,塑性变形区为细长的纤维组织,齿形截面硬度分布具有一定的规律性。试验所得零件无缺陷,硬度、耐磨性等较传统的切削加工花键大大提高,可满足使用要求。

Cold rolling precision forming process of spline is one of the high-efficiency,precision and non-chip advanced manufacturing technologies.It has the characteristics such as high forming efficiency,energy-saving,low material consumption and better forming properties of components.The process and principle of involute spline is analyzed,the unit average pressure contacting area,rolling billet diameter,rolling force and moment are solved.Experiments of the cold rolling precision forming on involute spline are carried out.Experimental results show that dramatic plastic deformation takes place on the upper surface of the workpiece during the cold rolling process of spline,while the influence on the inner materials are very small.The grains are distributed as a flow line pattern along the tooth profile,and the grains in the plastic deformation zone present a fine and long fibrous state.The hardness on the section of the tooth outline is regularly distributed.Compared with the spline components obtained from conventional cutting method,the hardness of the spline is greatly increased,therefore,comprehensive mechanical property such as wear resistance and impact resistance are greatly improved.It can be shown from the precision measuring and hardness testing of the tooth outline section that the components obtained by the experiments are free of defects,and the application requirement can be satisfied.