采用波形端面凸模的齿轮精锻工艺优化

采用数值模拟和物理试验相结合的方法，对直齿轮精锻工艺进行了分析。试验结果既说明此工艺方案可行，也验证了数值模拟的可靠性，为该工艺方案的优化设计奠定了基础。结合正交试验设计方法和数值模拟技术，以分流角、凸模成形角、反向凸模成形角和分流距4个模具设计的关键参数作为设计变量，以成形时所需工作载荷最小为优化目标，对工艺方案进行了优化。最后引入浮动凹模设计的思想，模拟了采用浮动凹模结构的优化方案的成形过程，采用浮动凹模的优化方案与传统方案和优化方案的模拟结果的对比分析发现，采用浮动凹模可以进一步降低工作载荷。

Optimization of the Forming Process in Net-shape Forging of Gears with Wave-shaped Punches

The forming process was analyzed by the method of numerical simulation followed by physical experiments. The results of experiments show the feasibility of the forming scheme and confirm the reliability of numerical simulation, and it will lay a foundation on optimization of the scheme. The method of combination of orthogonal experimental design with numerical simulation was used to optimize the scheme with four key parameters for die design, and the optimal scheme with the minimum service load was found. Finally, the idea of floating die was introduced to substitute for conventional fixed die. To compare the conventional scheme with the optimal scheme, the optimal scheme with floating die structure was also simulated, the deformation process of workpiece and forming load were investigated, and the service load was further decreased by floating die.