杯形内啮合齿轮旋压成形的数值模拟

采用强力旋压设备加工杯形内齿轮,由于芯模外表面呈阶梯状,且使用圆盘形坯料一次成形,工艺难度较大,产品出现了裂纹、内齿充填不足等缺陷。采用三维弹塑性有限元法模拟了变形过程,定性地分析了产品缺陷产生的原因。结果表明,在内齿根部受到旋轮的作用力较大,内齿边缘为拉应力状态,导致坯料易出现裂纹;材料主要表现为轴向流动趋势,造成内齿顶部填充不满。通过改进芯模结构及调整工艺参数,得到了合格的产品。

Spin-forming numerical simulation of cup-shaped inner meshing gear

The cup-shaped inner meshing gear was deformed by power spinning machine.Product defects,such as cracks,filling shortage of inner meshing gears appeared because of difficult process of stepped surface of mandrel and one-pass spinning with disc-shaped workpiece.A 3D finite element elastic-plastic model was used to analyze the gear spin-forming.The cause of product defects was studied qualitatively.The results show that the roll-pressing force on inner gear root is much higher,and tensile stress appears at th...