齿轮轴齿形轧制成形的模具设计与实验

Die design and experiment for forming the teeth of shafts by rolling

将齿轮的轧制成形与传统的楔横轧原理相结合,在轧制成形轴类零件的同时实现齿形部分的轧制成形,不仅可以实现齿轮轴零件的近净成形,而且可以提高齿的承载能力及使用寿命.在轧制齿形部分的过程中,对轧件的进给采用分段阶梯式进给方式,轧件在模具的带动下以自由分度方式进行轧制.通过数学模型和实验,给出了轧制各阶段模具齿距的计算方法和变化规律、模具的齿形设计方法、模具对轧件首次分度时最小进给量的计算方法以及轧制各阶段进给量的变化规律.用De-form-3D数值模拟仿真软件模拟轧制过程,在H630轧机上轧制出模数m=2,齿数z=20,压力角a'=20°的齿轮轴上的齿形,实验证明在楔横轧机上轧制齿轮轴上的齿形是可行的.

Combining the theory of wedge cross rolling（WCR） with forming gears by rolling,a method was proposed to form teeth simultaneously when rolling gear shafts.The method can not only realize the near net forming of gear shafts,but also improve the mechanical properties and service life of teeth.In the process of forming teeth by rolling,the feed was not continuous but intermittent,and workpieces were compelled to roll in free graduation under the rotation of dies.The calculation method and change law of die tooth pitch,the design of die tooth forms,the calculation method of the minimum feed at the first half circle and the law of feed change in each stage of rolling were presented on the basis of mathematical models and experiments.The rolling process was simulated by numerical software Deform-3D,with which the dies can be correctly designed.A toothed shaft with the module of the gear m=2,the number of teeth z=20 and the pressure angle a′=20° has been successfully formed with the H630 rolling tool.It is proved that forming teeth on gear shafts by wedge cross rolling is feasible.