大直径带毂直齿轮冷精密成形数值模拟及工艺分析

目的研究大直径带毂直齿轮冷精密成形新工艺。方法根据大模数大直径带毂直齿轮结构特点,提出了冷精密成形的难点和解决基本方法。基于分流减压和多工步成形原理,提出了3种可行工艺方案。采用Deform软件对工艺方案进行数值优化模拟,分析了方案二锻件成形过程的速度矢量、温度、应力和模具应力,阐述了成形原理。结果采用优化的新工艺可以减小载荷降低模具应力,齿形金属充填饱满。结论巧妙的分流面设计使大直径带毂直齿轮冷精密成形成为可能,新工艺能够为生产实践提供指导意义。

Numerical Simulation and Process Analysis of Cold Precision Forging for Large-diameter Spur Gears with Hub

Objective To study the new cold precision forging process of large-diameter spur gear with hub. Methods Based on the geometric feature of large module and large-diameter spur gear with hub, difficulties in cold precision forming and the corresponding solving methods were proposed. Based on the principle of distributary and decompression and the multi-step forming, three feasible technology schemes were put forward. The processes were numerically simulated using Deform-3D, different process schemes of different stages were analyzed. Further, the velocity vector, temperature, equivalent stress and die stress of scheme 2 were analyzed, and the forming principle was explained. Results The new optimal process could reduce the load and the die stress, and the tooth-shaped metal was fully filled. Conclusion The ingenious design of flow diversion face makes the cold precision forming of large-diameter spur gears with hub possible, and the new process can provide guidance for production practice.