主动螺旋锥齿轮双向对挤高效精密成形新工艺

New process of high efficiency and precision forming at two-way extrusion of spiral bevel driving gears

根据主动螺旋锥齿轮形状特点和成形工艺要求,提出一种新的成形工艺:双向对挤高效精密成形。数值模拟结果表明新工艺成形主动螺旋锥齿轮过程中齿型腔可以均匀、顺利的完成填充,所成齿形良好,无明显缺陷出现。载荷-行程曲线变化正常,变形过程可大致划分为3个阶段:自由变形、充满和角隅充填。与传统的单向闭塞模锻、单件成形工艺的载荷-行程曲线对比,载荷值降低了18%。等效应力在模具承受范围内,无破坏现象出现,证明材料流动性较好、新工艺可行。通过物理模拟实验,得到了齿形轮廓清晰、充填饱满、无折叠、无开裂等缺陷的铅质试件,实验结果与模拟结果基本吻合。

According to the shape characteristics and forming process requirements of the spiral bevel driving gears,a new forming process was proposed:high efficiency and precision forming at two-way extrusion.The numerical simulation shows that the tooth cavity can be filled evenly and smoothly and the tooth shape is perfect in the new process of forming the spiral bevel driving gears,no obvious defect appears.The load-stroke curve of new process changes normally,and the deformation process can be divided into three stages,which are free deformation,full filling and corner filling stage.Compared with the load-stroke curve of the traditional one-way flashless die forging and single part forming process,the load value is reduced by 18%.The effective-stress is in the mold bearing range and no destructive phenomenon appears,which proves that the material fluidity is perfect and the new process is feasible.Through physical simulation tests,the test-piece with clear profile,full filling,no folding,crack and other defects is obtained,and the test results are in agreement with the simulation results.