车用齿轮毛坯多工位精密热模锻工艺分析及模具设计

Process analysis and die design of multi-station precision hot die forging for automotive gear blank

设计了某型车用齿轮坯多工位精密热模锻工艺过程,并利用有限元法对设计的成形工艺过程进行了数值模拟分析,获得了锻压成形各个工位的最终变形图、行程载荷曲线和等效应力图。在此基础上,对模具结构方案和模膛进行了设计,并利用扬力集团制造的HFP2500热模锻生产线进行了试模和小批量自动试生产。结果表明,设计的方案能基本满足生产要求,但部分产品仍存在毛刺、变形等缺陷。结合试验和仿真结果,针对产品的缺陷提出了解决方案,对模具结构方案进行了优化改进。通过模具制造、试模和批量生产,锻件产品达到产品要求。

The process of the multi -station precision hot die forging for automotive gear blank was analyzed and then simulated with finite element method. The deformation plot, load curve, and stress status were obtained. Based on this, the structure and dimension of the die were designed. With a HFP2500 hot die forging production line produced by Yangli Group Corporation Ltd.,the rationality and validity of the design were evaluated. Results showed that the design can meet the requirements, but some of the products still have defects such as burr and deformation. Based on the results of the trail and simulation, the solution to these defects was proposed, and the structure of the die was improved. The dies were manufactured and tested again by mass production, the result showed that the products meet the requirements.