直齿圆锥齿轮冷闭塞锻造数值模拟分析

Numerical Simulation Analysis of Cold Closed-Die Extrusion Forging for Straight Bevel Gear

轿车上的直齿圆锥齿轮尺寸精度与产品质量要求很高 ,难以采用常规的塑性加工技术成形。冷闭塞锻造技术是近年发展起来的精密成形技术。以捷达轿车差速器行星齿轮为例 ,对冷闭塞锻造成形过程进行了数值模拟 ,分析了成形过程中的金属流动充填规律以及力学量场分布情况 ,对数值模拟中的一些关键技术问题进行处理 ,并进行冷闭塞锻造工艺实验研究。结果表明数值模拟分析准确 ,冷闭塞锻造工艺与模具设计合理 ,液压模架工作稳定可靠。

Straight bevel gears used in car differential have strict requirements for dimensional precision and quality, it is difficult to form accurately them by the traditional forging techniques. Differential satellite gear of car Jetta is illustrated in the paper and the 3D large deformation FEM is successively adopted to complete numerical simulation for the cold closed-die extrusion forging of the gear, which was developed lately. Some key problems in numerical simulation are considered, the flowing and filling regularity is analyzed, the strain and stress field distribution is obtained at different deforming stages. The technology is researched experimentally on hydraulic die-shelf of closed-die extrusion forging. The results show that numerical simulation is effective and satisfactory, forging process and the die cavity design are reasonable and the die-shelf system has functional reliability. The above mentioned have instructive significance for the application to practical production.