内外局部约束下内齿圈滚轧成形

提出一种内外局部约束高效滚轧成形内齿圈新工艺，完成相关工艺构架并分析了其成形过程内外滚轧模具及工件的运动特征。搭建了采用2对滚轧模具的内齿圈滚轧试验平台，实现了内齿圈滚轧；建立多对滚轧模具内外局部约束下内齿圈滚轧过程有限元模型，完成了采用2对滚轧模具和3对滚轧模具的内齿圈滚轧过程有限元分析。试验与有限元结果表明，齿形形状完整、轮廓清晰，达到了设计齿高要求，内齿圈滚轧成形工艺可行；和试验获得齿高相比，有限元模型对齿形预测误差小于5%；通过适当的模具和坯料几何参数调整，可控制成形齿高、改善端面成形质量。研究结果对内复杂型面零件的高效省力成形工艺具有理论意义和参考价值。

Rolling Forming Process with Internal and External Local Constraints for Inner Ring Gear

A new efficient rolling method with internal and external local constraints for manufacturing inner ring gear has been developed in this study. The frame of the new rolling process has been constructed, and the motion characteristics of inner rolling die, outer rolling die and workpiece are analyzed. The experimental platform with two pairs of rolling dies is developed, and the rolling process of inner ring gear was implemented. The finite element (FE) model of the rolling process with internal and external local constraints for inner ring gear is developed, and the finite element analyses with two pairs and three pairs of rolling dies are carried out. The experimental and FE results indicated that the profile of inner gear is full and clear, and the height of inner gear meets designed height, so the proposed rolling process of inner gear is feasible. Compared with the height of inner gear obtained by experiment, predictive error of FE model is less than 5%. By means of proper adjustments for geometries of die and billet, the rolled height of inner gear can be controlled and the forming quality of end of inner gear can be improved. The results provide a theoretical basis and useful guideline for manufacturing inner complex-profile part with high efficiency and saving force.