基于Deform-3D的传动齿轮冷挤压成形工艺研究

Study on Cold Extrusion Forming Technology of Transmission Gear Based on Deform-3D

传统的冷挤压工艺往往根据经验经过反复的试模修模后加以确定,生产周期长、成本高。基于Deform-3D软件,针对传动齿轮挤压出现的端部塌角磨损问题进行了数值模拟分析,优化成形工艺为一次复合挤压成形。分别对两种方案(优化的一次复合挤压成形和原有的正挤、镦挤两步成形)中的最大应力、最大应变、最大整体流动速度进行了分析。模拟结果表明,一次复合挤压成形同样可以得到形状精确的传动齿轮,而且具有更好的金属流动性能,说明传动齿轮一次冷挤压成形是可行的。

The traditional cold extrusion process is often determined according to experiences and by repeatedly testing and repairing dies. Its production cycle is long, and costs is high. Wear problems of end comer of transmission gear extrusion were numerically simulated. Forming process was optimized into a composite extrusion forming based on Deform-3D software. The maximum stress, the maximum strain and the maximum total-velocity in two kinds of scheme （optimized one step composite extrusion forming and the original two steps forming of the direct extrusion and the upsetting extrusion） were analyzed respectively. Simulation results show that the shape precision of gear can also be obtained by one step composite extrusion forming. And it has better the metal flow properties. It illustrates that the one step cold extrusion of transmission gear is feasible.