结合齿冷锻工艺分析及参数优化

利用Deform-3D软件对结合齿的冷锻成形过程进行了模拟,应用正交模拟试验以及工程试验相结合的方法,对某汽车变速箱结合齿冷锻工艺及参数优化进行研究,对预成形制件主要几何参数进行优化。研究结果表明:采用制定的冷锻预成形加精整倒锥工艺是可行的;凸台直径是影响成形力大小的最主要因素,其次是圆角半径,而齿形长度、内孔直径及凸台长度对成形力的影响较小;优化结果是当齿形长度A=6.5mm、内孔直径B=45mm、凸台直径C=62mm、凸台长度D=11mm、圆角半径E=2mm时,成形载荷最小。以优化结果为依据,成功实现了该类零件的冷锻成形。

Analysis and parameter optimization of integrate gear cold forming

The cold forming process of integrate gear was simulated by Deform-3D software.The pre-forming process formability of integrate gear and the optimization of parameters were studied by using combined method of orthogonal simulation test with engineering test.The results show that the established process is feasible.The boss diameter is the key factor for the process formability,while the fillet radius,gear length,bore diameter and boss length have a less influence to the process formability.The optimized parameters are listed as follows: gear length A=6.5 mm,bore diameter B=45 mm,boss diameter C=62 mm,boss length D=11 mm,fillet radius E=2 mm,which provides the least forming load.On the basis of the optimized parameter,cold forming for this type of part was carried out successfully.