圆柱直齿轮冷精锻成形工艺数值分析及优化

Numerical Analysis and Optimization of Cold Precision Forging Process for Cylindrical Spur Gears

基于现有圆柱直齿轮冷精锻工艺,增加“飞边孔”工艺方案B和“分流槽”工艺方案C,结合实际将“飞边孔”及“分流槽”开设的尺寸较小,但仍能使最大成形载荷下降超100kN,验证了两种工艺方案对降低成形载荷有显著效果;利用Deform-3D软件对3种工艺方案进行分析,得到了工艺方案B、C较工艺方案A的应力值更小且分布均匀,说明工艺方案B、C齿轮成形质量优于工艺方案A;对摩擦系数0.1、0.2、0.3和上模下行速度1mm/s、5mm/s、10mm/s进行成形载荷分析,成形载荷最大为2,070kN,最小为1,489kN,下降28%,得到了上述工艺参数范围内成形载荷的分布规律及范围,为实际工艺参数选择提供了理论依据。

Based on the existing cold precision forging process of cylindrical spur gears,this article adds"flash hole"process plan B and"diversion groove"process plan C.combine with practice,the"flash hole"and"diversion groove"are set with smaller sizes,but can still reduce the maximum forming load by more than 100kN.This verifies that the two process plans have significant effects on reducing the forming load.Using Deform-3D software to analyze three process plans,it was found that the stress values of process plans B and C were smaller and evenly distributed compared to process plan A.This verified that the gear forming quality of process plans B and C was better than that of process plan A.The forming load analysis was conducted on the friction coefficients of 0.1,0.2,0.3,and the upper and lower die speeds of 1mm/s,5mm/s,and 10mm/s.The maximum forming load was 2,070kN,and the minimum was 1,489kN,a decrease of 28%.The distribution pattern and range of forming load within the above process parameter range were obtained,providing a theoretical basis for the selection of actual process parameters.