准双曲面齿轮冷摆辗方案回弹误差补偿

Compensation of springback error in a cold rotary forging method for hypoid gear

提出一种冷摆辗方案,该方案简化了模具结构,采用局部线接触连续塑性成形.采用位移修正算法构建回弹误差补偿迭代系统,对冷摆辗模具进行修正来降低回弹误差.该系统的特点是首先用修正算法预估下一次冷摆辗假设无回弹时工件的几何形状,然后由冷摆辗模具设计原理推出所需要的新冷摆辗模具.基于弹塑性有限元法基本理论,借助有限元数值模拟技术进行实例验证,分析结果证明:该回弹误差补偿迭代系统只需3次迭代工件误差已经在允许的范围内,因此其可大大的缩短生产周期和成本.

The authors put forward a cold rotary forging mthod, and the method simpli- fies the die structure, adopts the local line contact continuous plastic forming. The algorithm of displacement adjustment was used to construct the compensation iteration system of spri- ngback error, which was used to correct springback error of the rolling die. The feature of the system was first estimating the workpiece geometry using correction algorithm when the workpiece was assumed no springback, then obtaining the new rolling die with the design principle of rolling die. Based on the basic theory of elastic-plastic finite element method, in- stance of verification was carried out with the aid of finite element numerical simulation tech- nology. The results of this research confirm the compensation iteration system of springback error just need three iterations to make the workpiece tolerances within the permitted scope, therefore it can greatly shorten the production cycle and cost.