基于浮动凹模和分流原理的圆柱直齿轮冷精锻成形过程有限元模拟

Numerical Simulation of Cold Forging of Spur Gear Based on Floating-die and Hole Divided-flow Principle

圆柱齿轮冷精锻成形时变形抗力高,流动性差,齿形填充困难,模具磨损严重,寿命低,阻碍了冷锻工艺的推广。以大模数重卡汽车用圆柱直齿轮为研究对象,利用分流原理结合浮动凹模结构设计了直齿轮预锻及终锻二步工艺方案及模具工装;在此基础上,利用DEFORM-3D软件建立了圆柱直齿轮的冷精锻成形的有限元模型,对齿轮成形过程进行了数值模拟,分析了成形载荷、应力及应变场的变化规律,为模具设计及高性能齿轮的锻造提供一定的指导和参考。

The precision cold forging of spur gear forms high deformation resistance,poor fluidity,tooth filling,die wear,and low life,which prevents the popularization of cold forging process.Taking the spur gear with big modulus as the research object,using flow based on the principle combined with floating die structure,the design of pre-forging and finish-forging with two-step process and molds were finished.On this basis,using DEFORM-3D software,the finite element model of cold precision forging of spur gear was established to carry out the numerical simulation of gear forming process,and analyze the variation law of forming load stress and strain field,which provides some guidance and reference for mould design and forging of high performance gears.