渐开线齿形零件精冲尺寸精度分析及工艺参数优化

Dimensional precision analysis and process parameter optimization on fine blanking for involute toothed parts

采用Deform-3D软件对某汽车变速箱零件渐开线花键孔的精冲成形进行模拟,分析花键孔精冲有限元模型的结构特点,以点的位移量作为花键孔精冲模拟尺寸精度的评价标准。采用全面试验设计法研究凸凹模间隙、凸模圆角半径和压边力3个工艺参数对精冲成形结果的影响,获得最优工艺参数组合为:凸凹模间隙为0.04 mm、凸模圆角半径为0.4 mm和压边力为724 kN,利用极差分析方法得出各因素对花键孔精冲尺寸精度的影响程度大小依次为凸凹模间隙>凸模圆角半径>压边力。采用插值法对最优工艺参数组合模拟试验中的凸模进行应力分析,并预测凸模的使用寿命为4825次,符合设计预期。最后,采用优化后的工艺参数组合进行了实际花键孔精冲试验,花键孔的成形尺寸精度得到了明显提升。

Deform-3D software was used to simulate the fine blanking for involute spline hole of an automobile gearbox part,and the structural characteristics of finite element model for the spline hole fine blanking were analyzed,the displacement amount of point was taken as the evaluation standard of the dimensional precision for spline hole fine blanking simulation.The influences of three process parameters,such as clearance between punch and die,fillet radius of punch and blank holder force,on the fine blanking results were studied by comprehensive experimental design method,and the optimal combination of process parameters was obtained as follows:the clearance between punch and die was 0.04 mm,the fillet radius of punch was 0.4 mm and the blank holder force was 724 kN.By using range analysis method,the influence degree of each factor on the dimensional precision of fine blanking spline hole was in the order of clearance between punch and die>fillet radius of punch>blank holder force.The stress analysis of punch in the optimal process parameters combination simulation experiment was carried out by interpolation method,and the punch service life was predicted to be 4825 times,which was in line with the design expectation.Finally,the actual spline hole fine blanking experiment was carried out with the optimized parameters combination,and the dimensional precision of spline hole forming was obviously improved.