汽车差速器锥齿轮的温锻制坯/冷摆辗成形加工技术研究

为提高差速器锥齿轮的齿部强度和静啮合特性,达到少无切削加工及大批量生产的目的,采用温锻制坯、锻件余热退火与冷摆辗成形相结合的精密成形工艺生产差速器锥齿轮精锻件;对变形程度的分配、成形工艺参数的选择、高精度冷摆辗模具的设计与加工等关键技术问题进行了分析。结果表明,采用该工艺生产的差速器锥齿轮精锻件,较好地解决了差速器锥齿轮制造过程中存在的齿轮精度差、齿部强度低、模具寿命低、设备投资大等问题,为提高差速器锥齿轮的国产化率、减轻差速器的重量进而减轻汽车的自重等奠定了技术基础。

Research on Warm Forging/Cold Orbital Forming Technology for the Straight Bevel Gear in Differential Case

In order to improve the resistance to static rupture and bending fatigue,and achieve the goal of near-net-shape forming and mass production,a combined forming process of warm forging for blanks,softing annealing for blanks with its remainder temperature and cold orbital forming for the gear teeth were used to manufacture the precision forgings for the straight bevel gears.The key technical problems including the distribution of deformation degree,choice of the main forming parameters and design of die sets etc. were analyzed exhaustively.The experimental results and mass production show that the key technical problems including the tolerances and strength of gear teeth,the life of dies and the investment of equipment etc. are solved properly by this combined forming process.Thus,it is one of the most economical,effective manufacturing technology for the straight bevel gear of differential case.