从动齿轮异形环坯锻件整形工艺

Shaping technology for forgings of special-shaped ring blank of driven gear

以内径Φ105 mm、外径Φ170 mm、质量约4 kg的从动螺旋齿轮坯为研究对象,采用开式双辊摆辗方式对从动齿轮坯进行整形,通过对毛坯形状尺寸的研究,使锻件单边余量控制在1 mm以内,可极大地提高材料利用率,并在保证成品率的基础上大大提高了机加工的效率,具有很好的经济效益。利用Deform-3D软件分析了从动螺旋齿轮坯摆辗整形工艺,通过对毛坯尺寸的控制,可以得到下端面无飞边、上端面少飞边且内外径符合要求的环件,提高了24.59%的材料利用率,并且减少了机加工工序、简化了工艺过程、提高了生产效率、较大地提高了齿轮坯的精度。以此为依据指导生产实践,缩短了生产周期。通过整形试验得到了符合要求的终锻件,证明了该摆辗整形工艺的合理性和可行性,并进行了小批量试生产,试验结果良好。

For the driven spiral gear blank with internal diameterФ105 mm,external diameterФ170 mm and weight about 4 kg,the driven gear blank was shaped by open-type double-roller rotary forging.Based on the research of the shape and dimension of blank,the unilateral allowance of forgings was controlled within 1 mm to greatly increase the material utilization,and on the basis of ensuring the product qualification rate,the efficiency of machining was improved greatly to obtain the good economic benefit.Then,the rotary forging and shaping process of driven spiral gear blank was analyzed by Deform-3D software,and the qualified forgings without flash on the lower end face,with less flash on the upper end face and inner and outer diameters in accordance with requirements were gained by controlling the blank dimensions to improve the material utilization rate by 24.59%,which reduced the machining steps,simplified the process,increased the production efficiency and significantly improved the accuracy of gear blank.Thus,on this basis,the production practice was guided,and the production cycle was shortened.Furthermore,the final forgings were obtained by shaping test,the rationality and feasibility of the rotary forging and shaping process were proved.Finally,the small batch trial production was conducted,and the test results were good.