矩形直齿轮热锻工艺有限元模拟

FE simulation of hot forging process for rectangular spur gear

针对大尺寸矩形直齿轮,提出了镦粗预锻终锻3工序"一火"连续锻造的工艺方案。利用有限元软件Deform-3D建立矩形直齿轮热锻有限元模型,并模拟其成形过程。根据模拟结果探讨成形过程中的温度场、等效应变场、材料流动情况及成形载荷的变化规律。在6.3MN高能螺旋压力机上成功试制出矩形直齿轮锻件,工艺试验与模拟结果具有较好的一致性,锻件形状满足设计要求、无折叠缺陷,证明该工艺方案切实可行。

The process plan of upsetting-pre-forginfffinal forging was presented for the rectangular spur gear with large dimension. The FE model of hot forging process was constructed with the finite simulation software of Deform-3D, and the whole forging process was simulated. Then the changing rules of temperature distribution, effective strain field, velocity field of material and forging load in the process were investigated. Finally, the spur gear forging part was forged on a 6.3 MN high energy screw press and a good agreement was found between the simulation and experimental results. The forging parts with satisfied dimension and without any folding defect were obtained, which show that the multi-stage hot forging process is feasible.