从动螺旋锥齿轮双锥辊辗压成形工艺参数优化

针对双锥辊辗压螺旋锥齿轮成形过程中型腔下模受力过大以及齿形充填高度不够的问题,首先,运用DEFORM-3D有限元软件对从动螺旋锥齿轮齿坯双锥辊辗压过程进行了模拟分析,研究了摩擦系数、辗压温度、凹模型腔进给速度对凹模型腔等效应力和Z方向成形齿高的影响;其次,采用正交试验设计方法,以凹模型腔等效应力和Z方向成形齿高为优化指标,得到了最佳工艺参数,并进行了数值验证;最后,通过数值计算分析以及与文献中研究结果进行比较分析,证明了从动螺旋锥齿轮双锥辊辗压成形工艺的可行性。结果表明:当摩擦系数为0.2、辗压温度为900℃、凹模型腔进给速度为2 mm·s~(-1)时,模具型腔受力最小,齿形的充填饱满,高度达到最高。

Optimization on process parameters of double cone roller rolling for driven spiral bevel gear

For the problems of excessive force acting on the concave cavity and insufficient filling of tooth height during the forming of the double cone roller rolling for spiral bevel gear, the rolling process of double cone roller for the driven spiral bevel gear was simulated by fi-nite element software DEFORM-3D firstly, and the influences of friction coefficient, rolling temperature, feeding velocity of concave cavity on the equivalent stress of concave cavity and the forming tooth height along Z-direction were studied. Secondly, the optimum process pa-rameters were obtained and verified numerically by the orthogonal test design method with the optimized indexes of the equivalent stress of concave cavity and the forming tooth height along Z-direction. Finally, the feasibility of double cone roller rolling process for driven spiral bevel gear was proved by numerical analysis and compared with the results in the literature. The results show that when the friction coeffi-cient is 0. 2, the rolling temperature is 900℃, and the feeding velocity of concave cavity is 2 mm·s-1 , the force of concave cavity is the smallest, and the filling of tooth shape is full with the highest tooth height.