载重汽车用直齿轮冷挤压工艺参数多目标优化  

Multi-objective optimization of cold extrusion process parameters for spur gear of camion

作　　者：梁强[1] 周杰[1] 何雄[1] 夏泽雨 刘正伟 LIANG Qiang;ZHOU Jie;HE Xiong;XIA Zeyu;LIU Zhengwei(College of Material Science and Engineering, Chongqing University, Chongqing 400044, China;Chongqing Zhonglian Gear Transmission Co. Ltd.,Chongqing 402247, China)

机构地区：[1]重庆大学材料科学与工程学院,重庆400044 [2]重庆众联齿轮传动有限公司,重庆402247

出　　处：《中南大学学报（自然科学版）》2017年第12期3216-3223,共8页Journal of Central South University:Science and Technology

基　　金：国家自然科学基金资助项目(51275543);重庆市科委应用开发项目(cstc2014yykfC70003)~~

摘　　要：针对大模数直齿轮冷挤压成形后端面加工余量大、齿顶塌角大和成形载荷大的问题,以齿顶圆角、入模角、劈分厚度、定径带长度为优化变量,应用响应面法和有限元数值模拟对齿轮冷挤压成形工艺参数进行多目标优化。以减小齿轮端面加工余量、提高齿顶充填性和降低成形载荷为目标,分别建立3个目标函数的二阶响应面模型,通过在可行变量空间内寻优,将优化后的最优工艺参数进行验证。研究结果表明:得到的模型预测精度高,能较好地描述3个目标函数关于设计变量的响应。大模数直齿轮冷挤压成形最优工艺参数为:齿顶圆角1.6 mm、入模角40°、劈分厚度2 mm、定径带长度15 mm。采用最优工艺参数加工的试样的端面加工余量降至1.91 mm,齿顶塌角量降至0.29 mm,成形载荷降低18.2%。工艺实验证明采用多目标优化得到的工艺参数可以获得合格的产品。Taking the defects such as large machining allowance of gear end-face,insufficient corner filling and large forming force in the process of cold extrusion of spur gear with large module as the research objects,the radius at tooth tip of die,die semi-angle,splitting thickness and length of die bearing were selected to be optimization variables.The response surface method(RSM)combined with finite element method(FEM)was used for the multi-objective optimization of cold extrusion process parameter.Aiming at reducing machining allowance,improving capacity of corner filling and lowering forming force,second-order response surface models of three objective functions were established based on the results of experiment design.The optimization graphs in the variable space were analyzed.The results show that the result models exhibit high prediction accuracy and can describe the response of the three functions on design variables accurately.The optimal process parameters are as follows:the radius at tooth tip of die is1.6mm;die semi-angle is40°;splitting thickness is2mm and length of die bearing is15mm.After the practical verification with optimized process parameters,the machining allowance of gear end-face reduces to1.91mm and the collapse amount of gear tooth reduces to0.29mm.The practical results indicate that with the result parameters obtained from multi-objective optimization,qualified products can be produced.

关 键 词：响应面法 大模数直齿轮 冷挤压 数值模拟 

分 类 号：TG136[一般工业技术—材料科学与工程]