带强制分齿的齿轮滚轧成形数值模拟方法研究

Numerical Method Study of Gear Rolling Process with Workpiece Drive System

齿轮滚轧是一种新型齿轮成形工艺,具有生产效率高、材料利用率高、轮齿机械性能好等优点。由于缺乏对带强制分齿的轴向滚轧工艺的研究,提出了带强制分齿的轴向滚轧工艺的数值模拟方法,并通过滚轧实验进行了验证。由于软件无法定义齿坯的主动旋转运动,推导了以轧轮公转代替齿坯自转的运动学模型,在有限元软件FORGE中建立了齿轮轴向滚轧有限元模型,从金属流动、应力分布等方面分析齿坯成形过程;最后,进行齿轮轴向滚轧实验,结果表明成形齿轮的齿形与数值模拟结果比较吻合,证明了运动学等效模型的正确性以及有限元方法的可行性。

Rolling process with axial infeed is an advanced forming technology of gear, whichhas the advantages of high production efficiency, high material utilization rate and good mechanical performance of gear teeth. Due to the lack of the study on gear rolling process with workpiece drive system, a numerical method of spur gear rolling process with workpiece drive system is proposed in this paper, and rolling experiment is used to verify the method. Rotational motion of the workpiece is hard to be defined in software, thus a kinematic model, the workpiece rotation is replaced by the rolling tool revolution, is deduced, and the finite element model is also built in FORGE. The forming process of workpiece is analyzed from metal flow and stress distribution. Finally, the rolling experiment with axial infeed is done, and compared result shows that the experimental tooth profile is close to the numerical simulation result, which proves correctnessof kinematic model and feasibility of finite element method.