直齿圆锥齿轮双向镦挤精密成形工艺的数值模拟研究  

Numerical Simulation Study on Two-way Upsetting-extrusion Precision Forming Technology of Straight Bevel Gear

作　　者：郭开元 张如华[1] 吴泽 GUO Kaiyuan; ZHANG Ruhua; WU Ze(School of Mechanical and Electrical Engineering, Nanehang University, Nanchang 330031, China)

机构地区：[1]南昌大学机电工程学院

出　　处：《热加工工艺》2018年第19期162-165,共4页Hot Working Technology

基　　金：江西省发明专利研发引导项目(20143BBM26105);江西省教育厅科技计划项目(GJJ13192)

摘　　要：基于挤压成形提出了直齿圆锥齿轮的双向镦挤精密成形工艺。将传统的＂闭塞挤压＂中上、下凹模优化为整体式凹模,利用可增大镦挤面积的齿形结构设计上、下凸模。根据＂有效摩擦＂原理,利用有限元模拟软件DEFORM-3D对直齿圆锥齿轮的双向镦挤成形和单向镦挤成形进行了数值模拟。结果表明,采用双向镦挤成形直齿圆锥齿轮,有利于齿形填充,与其单向镦挤成形相比,双向镦挤的上、下凸模载荷分别降低了55.6%和32.0%。通过物理试验对该方法的可行性进行了验证,成形出了无飞边、齿形充填饱满、轮廓清晰、无折叠、开裂等缺陷的直齿圆锥齿轮。研究结果可为直齿圆锥齿轮高效、节能、节材的近净成形技术提供参考。The two-way upsetting-extrusion precision forming process of the straight bevel gear was presented based on extrusion forming. The upper and lower concave dies in the traditional ＇block extrusion＇ was optimized as integral concave die.The upper and lower convex die was designed by using the tooth shape structure which increases upsetting and extruding area.According to the ＇effective friction＇ principle, the two-way upsetting-extrusion forming and one-way upsetting-extrusion forming of the straight bevel gear were numerically simulated by finite element simulation software DEFORM-3 D. The results show that the forming of the straight bevel gear by two-way upsetting-extrusion forming is advantageous to filling the tooth profile. Compared with one-way upsetting-extrusion, the upper and lower punch loads of two-way upsetting-extrusion are reduced by 55.6% and 32.0%, respectively. The feasibility of the method was verified by physical experiments. The straight bevel gears with non-flash, full tooth filling, clear outline, no folding and cracking and other defects were formed. The results can provide a reference for the near-net forming technology of straight bevel gear with high efficiency, energy saving and material saving.

关 键 词：直齿圆锥齿轮 精密成形 双向镦挤 数值模拟 

分 类 号：TG376[金属学及工艺—金属压力加工]