圆柱齿轮滚轧成形数值模拟与突耳控制

Numerical Simulation and Lug Control of Rolling Forming Motion Process for Cylindrical Gears

滚轧成形技术可有效提高金属材料利用率、改善齿轮疲劳强度。对直齿圆柱齿轮的滚轧成形技术进行研究,推导齿面方程,实现了齿面点计算,利用DEFORM软件对直齿圆柱齿轮滚轧成形过程进行了模拟仿真,分析了等效应力场、等效应变场以及滚轧力的变化情况,明晰了各个阶段最大应变发生于坯料齿形中点偏齿根处、应力最大值在模具轮和坯料的接触处这一规律;探索了滚轧中突耳缺陷的形成机制,研究了摩擦因数对突耳的作用规律,实现了面向突耳控制的摩擦因数的优选,为圆柱齿轮的滚轧成形加工提供了理论基础。

Rolling forming technology can effectively improve the utilization rate of metal materials and improve the fatigue strength of gears.The rolling forming technology of straight cylindrical gear was studied,the tooth surface equation was derived,and the calculation of tooth surface points was realized.The rolling forming process of straight cylindrical gear was simulated by using DEFORM software,and the changes of equal stress field,equivalent strain field and rolling force were analyzed.The law is clarified that the maximum strain of each stage occurs at the root of the midpoint of the blank tooth shape,and the maximum stress is at the contact between the mold wheel and the blank.The formation mechanism of lug defects in rolling was explored,and the action law of friction coefficient on lug was studied,the optimization of friction coefficient oriented to lug control was realized,which could provide a theory for the rolling forming of straight cylindrical gear.