直齿圆柱齿轮开放成形数值模拟

为了降低齿轮精密成形力,在对闭式镦挤成形齿轮分析的基础上,提出了直齿圆柱齿轮开放成形新方法,即开放式温镦挤-冷推挤复合成形工艺。用三维刚塑性有限元对闭式镦挤和开放成形两种直齿圆柱齿轮成形方法进行了数值模拟分析。结果表明,开放成形与闭式成形相比,可明显降低成形力,改善模具受力条件,提高成形工件的质量。并根据模拟所得载荷-行程曲线,计算出开放镦挤齿形变位系数为0.2时,成形力所作功最小,为“开放镦挤”齿轮凹模的设计提供了依据。

Numerical simulation on opened-die forming of spur gear

In order to decrease precision forming force of spur gear, at the base of analyzing closed-die forming, the method of opened-die forming has been brought forward, which is the opened-die warm upset-extruding and opened die cold push-extruding forming technique. 3D rigid-plastic finite-element is used to simulate the forging process in detail. The results showed that, compared with closed-die forming, opened-die forming can evidently decrease the forming force, meliorate the stress state of die, improve the quality of the formed spur gear. Furthermore according load-stoke curve we calculate the power of the load is least when the displacement factor is 0. 2, which provides basis for the gear die design of opened-die upset-extruding.