螺旋锥齿轮锻造成形过程数值模拟及其模具变形规律

Numerical simulation on forging process of spiral bevel gear and mold deformation law

为提高螺旋锥齿轮锻造工艺的制造精度和经济效益以及为工艺制定和模具设计提供指导,在工厂已有成形设备的基础上,提出了下料、镦粗-冲孔复合、辗扩、终锻成形的大模数螺旋锥齿轮锻造成形工艺。采用有限元法,通过数值模拟研究得到了终锻成形过程中的应力、应变等物理场量的演变与分布规律,验证了锻造工艺的可行性;通过数值模拟研究了终锻过程中模具齿形的不均匀弹性变形情况,为工艺的制定和模具的设计提供指导。研究发现:下模齿形在热力耦合的作用下产生不均匀变形,下模齿形的高度降低、螺旋线中点的螺旋角减小以及齿廓形状变窄,从而对齿轮齿形的成形精度产生显著影响。

In order to improve the manufacturing precision and economic benefit of spiral bevel gear forging process and provide guidance for process formulation and mold design,based on the existing forming equipment in the factory,the forging process of spiral bevel gear with large modulus including blanking,upsetting and punching compound,ring rolling and final forging was presented,and the evolutions and distribution laws of physical fields,such as stress and strain in the process of final forging were obtained through the numerical simulation by finite element method to verify the feasibility of forging technology.Then,the inhomogeneous elastic deformation condition of mold tooth profile was analyzed by the numerical simulation,which provided guidance for process formulation and mold design.The results show that the uneven deformation of tooth profile lower mold occurs under the thermo-mechanical coupling,the height of tooth profile for lower mold reduces,the spiral angle of helix midpoint decreases,and the shape of tooth profile narrows,which has a significant influence on the forming accuracy of gear tooth profile.