基于齿顶分流的铜制齿环热锻成形工艺方案设计  

Design on hot forging process scheme for copper gear ring based on tooth top shunt

作　　者：夏洪均[1,2] 唐全波[1] 李永亮 梁强 Xia Hongjun;Tang Quanbo;Li Yongliang;Liang Qiang(College of Mechanical Engineering,Chongqing Technology and Business University,Chongqing 400067,China;Engineering Training Center,Chongqing Technology and Business University,Chongqing 400067,China)

机构地区：[1]重庆工商大学机械工程学院,重庆400067 [2]重庆工商大学工程训练中心,重庆400067

出　　处：《锻压技术》2022年第7期20-27,共8页Forging & Stamping Technology

基　　金：重庆市教育委员会科学技术研究项目(KJQN201900836)。

摘　　要：以某款HMn64-8-5-1.5锰黄铜制齿环为研究对象,通过有限元模拟仿真,设计其热锻成形工艺方案并进行工艺实验验证。首先,通过等温热压缩实验获取HMn64-8-5-1.5合金在变形温度为873~1073 K、应变速率为0.01~10 s^(-1)及变形量为60%条件下的真应力-真应变数据,以此为基础,通过非线性曲线拟合构建其Hansel-Spittel本构模型。其次,应用该本构模型建立齿环热锻成形有限元模型,模拟仿真了该齿环热锻成形过程,分析得到花键齿齿尖处充填不饱满的原因为:金属充填花键齿型腔时,在齿尖处形成了封闭的空腔,从而出现憋气现象,导致齿尖处充填不饱满。最后,针对该问题提出一种齿顶分流的解决思路,即在原模具齿顶处设计分流槽。经数值模拟与工艺实验验证,采用该方法可以有效地解决齿环热锻成形后花键齿齿尖充填不饱满的问题。For the HMn64-8-5-1.5 manganese brass gear ring,the hot forging process scheme was designed by finite element simulation,and the process test was verified.Firstly,the true stress-true strain data of HMn64-8-5-1.5 alloy under the conditin of the deformation temperatures of 873-1073 K,the strain rates of 0.01-10 s^(-1) and the deformation amount of 60%was obtained by the isothermal hot compression tests,and on this basis the Hansel-Spittel constitutive model was constructed by nonlinear curve fitting.Secondly,a finite element model of the hot forging for gear ring was established by using the Hansel-Spittel constitutive model,and the hot forging process of gear ring was simulated.Furthermore,the reasons for the insufficient filling at the spline tooth tip were analyzed.When the metal filled the cavity of spline tooth,a closed cavity was formed at the tooth tip,and the phenomenon of suffocation occurred,resulting in insufficient filling at the tooth tip.Finally,in view of the above problem,a solution thought to the tooth top shunt was proposed,namely,a shunt groove at the tooth top of the original mold was designed.The results of numerical simulation and process test show that the problem of insufficient filling of spline tooth tips after hot forging of the gear ring can be effectively solved.

关 键 词：齿环 热锻成形 憋气 齿顶分流 Hansel-Spittel本构模型 

分 类 号：TG316[金属学及工艺—金属压力加工]