某同步器齿环热精锻成形工艺方案设计

Process scheme design on hot precision forging for a synchronizer ring

提出同步器齿环两种不同的热精锻成形工艺方案,借助有限元分析软件Deform-3D,模拟了两种工艺方案下齿环的热精锻成形过程,分析比较了两种方案中的金属流动规律和应变分布规律。模拟结果显示:工艺方案1的成形末期,在定位键与侧壁结合处变形较剧烈,该处存在两个方向的金属汇流,从而导致该处产生折叠缺陷;采用方案2,定位键最后充填,充填方式为金属的径向和轴向复合流动,定位键与侧壁的结合处不存在两个方向上的金属汇流,因此不会产生折叠缺陷。工艺试验表明,采用方案1成形的齿环在定位键与侧壁的结合处有明显的折叠缺陷,采用方案2成形的齿环充填饱满、未见折叠缺陷。数值模拟结果与工艺试验结果相吻合,数值模拟可以为实际生产提供指导。

The forming process schemes of two kinds of hot precision forging for synchronizer ring were proposed,and their forming processes were simulated by the finite element software Deform-3D. Then,the metal flow and strain distribution laws of two process schemes were compared. The simulation results show that at the end of forming process for the first process scheme,the deformation at the joint between positioning key and side wall is severe,and the metal confluence in two directions results in folding defect. However,for the second scheme,the positioning key is filled by a radial and axial composite flow at the final stage,and the metal confluence in two directions does not exist at the joint between positioning key and side wall. Finally,no folding defect is generated. The process experiments show that the synchronizer ring has obvious folding defect at the joint between positioning key and side wall by the first process scheme,and the synchronizer ring is filled sufficiently without folding defect by the second process scheme. Furthermore,the simulation results are consistent with the experiment results,and the numerical simulation can provide guidance for the actual production.