某档位齿轮坯精锻成形模具结构参数的数值模拟分析及优化

针对某档位齿轮坯在闭式精锻成形过程中径向筋部出现的充填不饱满和折叠的缺陷,为了优化金属的流动性,改善筋部的填充情况,获得性能优良的合格锻件,运用正交实验和有限元结合的方法,分析了模具筋部拔模斜度α、圆角半径R对成形过程的影响,得出了极限模具结构参数图。分析了不同区域模具结构参数对成形质量的影响,确定在区域D中的参数条件下,锻件无明显的充不满和折叠缺陷,并优选拔模斜度为1.3°、圆角半径为3 mm进行了实际生产验证。研究结果表明:锻件质量良好,筋部端面平整,底部无折叠缺陷,实际锻件与数值模拟结果相吻合。

Numerical simulation analysis and optimization on precision forging die structure parameters for a gear blank

For the incomplete filling and folding defects occured in the radial rib of a gear blank in closed-die precision forging, in order to optimize metal mobility, improve the filling condition and get qualified forgings,the influences of drafting angle α and fillet radius R on forging process were analyzed by combining orthogonal experiment with finite element method, and the critical diagram of mold structure was given.Then, the influences of different structural parameters on the forming quality were analyzed, and forging parts were without significant incomplete filling and folding defects under the parameters conditions in the zone D.At last,the actual production with the draft angle of 1.3° and the fillet radius of 3 mm was validated.The results show that the forgings are in good quality with flat rib face and are free of folding defects in the bottom.The actual forging part is consistent with the numerical simulation results.