挡位齿轮坯闭式精锻缺陷有限元分析与工艺优化  

Finite Element Analysis and Process Optimization in Closed Precision-forging for Shifting Gear Blank

作　　者：周杰[1] 张辉[1] 郑晓凯[1] 曾德涛[1] 

机构地区：[1]重庆大学材料科学与工程学院,重庆400044

出　　处：《农业机械学报》2013年第3期251-256,共6页Transactions of the Chinese Society for Agricultural Machinery

基　　金：科技型中小企业技术创新基金资助项目(101010620080022)

摘　　要：采用刚塑性有限元法,对挡位齿轮坯闭式精锻成形缺陷进行仿真预测分析。通过对模具局部型腔在不同的拔模斜度和圆角半径条件下成形过程的正交对比模拟,跟踪描述了各种缺陷的形成过程,分析了缺陷的成因,定量给出了不产生折叠、刮料、充不满等缺陷的极限结构工艺参数范围图;针对齿轮类锻件实际生产中筋部位置度精度较低以及成形载荷过高的问题,基于分流原理设计了分流精锻成形工艺方案,通过模拟分析金属的流动规律,位置度精度控制在0.08 mm以内,成形载荷也降低了20%～40%,经过生产试制分析,其试验结果与数值模拟吻合较好。Based on a rigid plastic finite element method, the surface defect of closed precision-forging process for shifting gear blank can be predicted. The metal forming process with different drafting angle and fillet radius in the die key part was simulated by using the orthogonal experimental method, and the initiation of surface defect was analyzed in detail. The reasonable forging critical diagram of shifting gear blank was given, which effectively eliminates fold and unfilled. Meanwhile, in view of the problems of the high position accuracy of ribs and the high forming load in actual practice, a new scheme of divided flow precision-forging was put forward, which can greatly improve rib position degree precision and reduce load. The accuracy of position degree was less than 0.08 mm, and the reduce load was reduced by 20% - 40%. The new scheme was put into actual practice and the key problems of a closed precision- forging process for shifting gear were solved. The reliability of the numerical simulation was verified.

关 键 词：挡位齿轮坯 闭式精锻 有限元分析分流工艺优化 

分 类 号：TG376.2[金属学及工艺—金属压力加工]