圆柱齿轮轴向滚轧变齿厚轧轮设计与工艺优化  

Design and process optimization of beveloid rolling dies in cylindrical gear through-feed rolling process

作　　者：马自勇 刘瑾 田英虎 王梓隆 杨伟 MA Zi-yong;LIU Jin;TIAN Ying-hu;WANG Zi-long;YANG Wei(School of Mechanical Engineering,Taiyuan University of Science and Technology,Taiyuan 030024,China;High-End Equipment and Rail Transit Technology R&D Center of Haian Taiyuan University of Science and Technology,Haian 226600,China)

机构地区：[1]太原科技大学机械工程学院,山西太原030024 [2]海安太原科大高端装备及轨道交通技术研发中心,江苏海安226600

出　　处：《塑性工程学报》2024年第12期61-75,共15页Journal of Plasticity Engineering

基　　金：国家自然科学基金资助项目(52205401);山西省应用基础研究计划青年项目(201901D211292);来晋工作优秀博士资助项目(20202036)。

摘　　要：针对传统轧轮在轴向滚轧过程中齿顶压入工件难、材料流动不畅及受力恶劣的问题,提出了一种圆柱齿轮轴向滚轧变齿厚轧轮几何设计方法。首先,结合齿轮啮合原理和齿条刀具加工方法,得到变变位系数工件的齿廓方程,推导出变齿厚轧轮切入段、精整段以及退出段齿廓方程。然后,利用具体齿轮实例和滚轧有限元模型,分析不同变位系数变齿厚轧轮对成形载荷、材料流动、齿廓误差的影响规律,确定变齿厚轧轮切入段变位系数的范围。最后,通过正交试验法分析轧轮转速、进给速度、摩擦因数对滚轧成形载荷与齿廓误差的影响,并展开齿轮滚轧成形试验。结果表明:切入段变位系数为-2~0、精整段变位系数为0、退出段变位系数为0~-0.5的变齿厚轧轮在成形载荷、材料流动速度和齿廓误差方面优于其余两种变齿厚轧轮,且与之匹配的较优工艺参数为:轧轮转速4.94 rad·s^(-1),进给速度0.5 mm·s^(-1),摩擦因数0.15,滚轧成形的齿轮分齿均匀、齿廓完整良好、尺寸符合要求。Aiming at the problems that the tooth tip of the traditional rolling die is difficult to press into the workpiece and insufficient ma-terial flow as well as adverse force in the through-feed rolling process,a geometric design method of the beveloid rolling dies was proposed in the cylindrical gear through-feed rolling process.Firstly,the tooth profile equation of workpiece with varying modification coefficients was obtained combining the meshing principle of gear and rack tool machining process,and the tooth profile equations of the cutting sec-tion,finishing section and exiting section of beveloid rolling dies were derived.Then,by using an example of gear and finite element mod-el of rolling process,the influence laws of the beveloid rolling dies with varying modification coefficients on the forming load,material flow and the error of the tooth profile were analyzed,and the range of modification coefficient in the cutting section of the beveloid rolling dies was determined.Finally,the influence of rotation speed of rolling dies,feed speed and friction factor on forming load in rolling process and tooth profile error was analyzed by orthogonal test method,and the gear rolling forming tests were carried out.The results show that the beveloid rolling dies with the modification coefficient of-2-0 in the cutting section,the modification coefficient of 0 in finishing sec-tion and the modification coefficient of 0--0.5 in exiting section are superior to the other two beveloid rolling dies in terms of forming load,material flow velocity and tooth profile error,and the optimal process parameters are as follows:the rotation speed of rolling die is 4.94 rad·s^(-1),the feed speed is 0.5 mm·s^(-1)and the friction factor is 0.15.The gears formed by rolling have uniform tooth splitting,complete and good tooth profile,and the sizes meet the requirements.

关 键 词：轴向滚轧 变齿厚轧轮 几何设计 正交试验 工艺优化 

分 类 号：TG335[金属学及工艺—金属压力加工]