杯形薄壁矩形内齿旋压成形数值模拟与试验

为研究主要工艺参数对齿轮成形状况的影响规律，并为参数优化和工艺设计提供依据，基于MSC.MARC有限元分析软件，对杯形薄壁矩形内齿旋压成形工艺过程和工艺特点进行分析，从而获得旋压成形时变形金属沿轴向、径向和切向的流动规律。结合工艺试验，定量地研究了主要工艺参数对齿高成形的影响规律，并对试验中出现的各种典型缺陷进行分析，提出有效的预防和改进方法。提出将包括轮齿的切向和轴向尺寸均匀程度等作为旋压成形内齿零件的主要质量评价指标。模拟和工艺试验结果表明，矩形内齿旋压成形时，压下量在一定范围内对齿高的成形影响显著，进给比对齿高成形影响不大。当工艺参数选择不当时，可能出现表面隆起或破裂、轮齿周向错移、周向高度不均和齿槽撕裂等缺陷。

NUMERICAL SIMULATION AND EXPERIMENTATION CUP-SHAPED THIN-WALLED INNER RECTANGULAR GEAR FORMED BY SPINNING

In order to investigate the effects of the main proc- essing parameters on the forming situation of the tooth depth, and provide foundation of the corresponding parameter optimi- zation and process design,the forming process and the process characteristics of the cup-shaped thin-walled inner rectangular gear formed by spinning are analyzed based on the MSC.MARC finite element analysis(FEA)software.Combin- ing with the processing experiment,the deformation mechanism of the deformed metal flow along the axial,radial and tangential directions are obtained;the effects of the processing parameters on the forming situation of the tooth depth are studied quantita- tively;the typical defects occurred during spinning are analyzed and the effective prevention methods are put forward.The main indexes to evaluate quality of the inner gear formed by spinning are presented,including the rear tooth dimension uniformity in the tangent and axial directions.Both the simulation and ex- periment results show that:During the spinning of the cup-shaped thin-walled inner rectangular gear,the effect of the blank radius reduction on the tooth depth is significant;The effect of the roller feed rate is slight.When adopting unreason- able processing parameters,the forming defects,such as the piling,fracture,stagger and uneven depth of the gear teeth along the circumferential direction,tearing of the gullet,may occur.