主动螺旋伞齿轮双向镦挤精密成形试验

为实现主动螺旋伞齿轮精密成形,并克服现有工艺存在的轮齿角隅填充欠饱满、模具结构复杂、成形力大等不足,根据"积极摩擦"原理采用了一种双向镦挤闭塞模锻新工艺。以一种齿数为10的主动螺旋伞齿轮为研究对象,分析了成形工艺特点并创建了三维模型,利用Deform-3D对成形过程进行数值模拟,得到载荷-行程曲线,结果表明,变形过程可划分为自由变形、大变形、充满3个阶段。与单向镦挤对比,双向镦挤的大、小端载荷值分别降低了14%和30%;并对所获等效应力、等效应变等信息进行了分析,为模具设计优化提供了依据。通过物理模拟试验,得到了无飞边、齿形充填饱满、轮廓清晰、无折叠和开裂等缺陷的铅质主动螺旋伞齿轮。

Experiment of two-way upsetting-extrusion precision forming of spiral bevel driving gear

In order to realize the precision forming of spiral bevel driving gear and overcome the deficiencies of existing shaping process of insufficient-filling tooth corner, complicated mold structure and large forming force, a new closed die forging process of two-way upsetting-extrusion was adopted according to the principle of effective friction. For the spiral bevel driving gear with ten tooth, the characteristics of forming process were analyzed, and a 3D model was created. Then, the forming process was numerically simulated by Deform-3D. The load-stock curve shows that the deformation process can be roughly divided into three stages as free deformation, large deformation and full filling stages. Compared with the one-way upsetting-extrusion, load values of larger and smaller ends of two-way upsetting extrusion decrease by 14% and 30% respectively, and the equivalent stress and equivalent strains are also analyzed, which provides a basis for die design and optimization. Furthermore, the spiral bevel driving gear with non-flash, full filling, clear outline, no folding and no cracking is obtained by physical simulation tests.