螺旋伞齿轮近净成形试验研究

Experimental research on near net shape forming of spiral bevel gear

采用Deform-3D有限元数值模拟与试验相结合的方法对螺旋伞齿轮的近净成形进行研究,提出初步的工艺优化解决方案。首先,通过有限元数值模拟分析,增设了预锻成形工序,将螺旋伞齿轮的近净成形工艺方案优化为“下料—退火—磷皂化—镦粗—退火—磷皂化—终锻”。在数值模拟基础上,对螺旋伞齿轮终锻成形进行了3水平2因素的正交试验,并在锻造试验结果基础上确定了合理的模具结构。结果表明,增加分流道能够有效减小成形压力;在优化后的模具结构中,压力机档位为1600 kN时能够实现螺旋伞齿轮的近净成形并且保证模具不被破坏。

Near net shape forming of spiral bevel gears was studied by the method combining Deform-3D finite element numerical simulation and tests,and the preliminary process optimization solution was proposed.Firstly,through the finite element numerical simulation analysis,the pre-forging forming process was added,and the near net shape forming process scheme of the spiral bevel gear was optimized to"cutting-annealing-phosphorus saponification-upsetting-annealing-phosphorus saponification-final forging".Based on the numerical simulation,the three-level two-factor orthogonal test of the final forging forming of spiral bevel gear was completed,and the reasonable mold structure was determined based on the results of forging test.The results show that increasing the flow channel number can effectively reduce the forming pressure;in the optimized mold structure,the near net shape forming of the spiral bevel gear can be achieved and the mold is ensured not to be damaged when the press position of the equipment is 1600 kN.