双联齿轮精锻成形工艺及数值模拟分析

针对双联齿轮的结构特点,提出了两种双联齿轮成形工艺,设计了坯料的合理形状,建立了三维有限元分析模型。通过工艺分析和不同工艺条件下的材料流动过程三维有限元动态仿真,研究了变形全过程的材料塑性变形行为、流动规律、几何尺寸变化以及成形件几何质量和缺陷等。对比有限元模拟结果发现:闭式模锻工艺齿形填充较差,产生折叠缺陷或充不满现象;挤压成形工艺齿形填充良好,是双联齿轮精锻成形的优选方案。研究结果为双联齿轮成形工艺实用化研究提供了理论指导或技术支持。

Numerical Simulation of Precision Forging Process for Duplicate Gear

Precision forging process of gears has advantage in saving material and energy consumption, reducing the cost and improving product quality. Duplicate gears have complicated geometries,and are difficult in precision deformation. Two forging processes of duplicate gear are put forward according to its structure characteristic. The appropriate geometries of billets are designed,and 3D FEM model for the precision forging processes is established. The forming laws, material plastic behavior, changed geometries and the qualities of the workpieces are explored by finite element simulation. According to the simulation results, the gear teeth are filled badly with fold flaw in close die forging process. The extrusion process in which the gear teeth are filled well is a feasible process. The study provides a technology foundation for practical production.