基于数值模拟的整体式结合齿轮复合冷整工艺研究

Research on Compound Cold-sizing Process of Integral Combined Gear Based on Numerical Simulation

基于多向模锻工艺原理提出了结合齿轮复合冷整工艺。首先,对结合齿轮进行工艺分析,并设计了不同的模具结构。然后,利用Deform-3D软件模拟了各方案下锻件的成形过程,对比选出了最优模具结构。最后,以轴向载荷和成形质量为优化目标采用正交试验优化了冷整前齿坯尺寸。结果表明:径向凸模采用浮动结构可使径向最大载荷降低31.5%,轴向载荷降低8%;采用优化后的齿坯成形锻件可使轴向最大载荷降低16.1%,且成形后齿部充填饱满无缺陷。

A compound cold-sizing process of a combined gear was proposed based on the principle of multi-directional die forging.Firstly,the process analysis of the combined gear was carried out,and different die structures were designed.Secondly,the Deform-3D software was applied to simulate the forming process under each plan,and the optimum die structure was selected by comparison.Finally,with the axial load and forming quality as the optimization goals,the orthogonal test method was applied to optimize the size of the blank before cold-sizing process.The results show that the floating structure of radial punch can reduce the maximum radial load by 31.5% and the axial load by 8%;the maximum axial load can be reduced by 16.1% by using the optimized tooth blank forming forgings,and the filling of the teeth after forming is full and without defects.