直齿圆柱齿轮双向镦挤精密成形工艺对比研究
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摘要
为实现直齿圆柱齿轮精密成形,并克服传统工艺存在的成形力大、模具结构复杂等一些不足,在已有齿形凸模双向镦挤成形直齿圆柱齿轮的基础上提出了另外2种改进的成形工艺,分析了不同成形工艺下端面摩擦力对载荷的影响,利用有限元模拟软件DEFORM-3D分别对3种成形工艺进行了数值模拟研究,并提出了一种优化的成形新工艺——无齿凸模双向镦挤精密成形.结果表明:采用无齿凸模镦挤成形直齿圆柱齿轮在载荷及模具结构方面优于有齿凸模镦挤成形,其中,无齿凸模双向镦挤较有齿凸模双向镦挤,上、下凸模载荷下降约55%;无齿凸模双向镦挤较非对称凸模双向镦挤,上、下凸模载荷分别下降约50%、38%;无齿模具加工制造更容易,强度更高;新工艺的等效应力最大值为3种方案中最小,而且等效应力变化正常,无破坏现象出现.对优化后的成形工艺进行了试验研究,得到了齿形轮廓清晰、充填饱满、无折叠、开裂等缺陷的铅质试件,试验结果与模拟结果基本吻合.
This paper aims to realize spur gears precision forming and overcome the deficiencies of traditional processes such as large forming force and complex mold structure. Two kinds of improved forming processes were proposed based on the existing spur gears forming of two-way upsetting-extrusion with tooth shape punch. The influence of friction on load under different forming processes was analyzed. The numerical simulation study of three kinds of forming processes was carried out by using the finite element simulation software DEFORM-3 D. It was proved that forming spur gears with toothless punch was superior to that with tooth shape punch in load and die structure, in which the load value of upper and lower punch of two-way upsetting-extrusion with toothless punch was decreased by about 55% compared with that with tooth shape punch. The load values of upper and lower punch of two-way upsetting-extrusion with toothless punch were decreased by about 50% and 38% compared with that with asymmetrical punch, suggesting that the manufacture of toothless punch is easier and with higher strength than tooth shape punch. The maximum effective-stress of the new process was the smallest among the three schemes, and the change was normal with no destructive phenomenon. Thus an optimized two-way upsetting-extruding precision forming process with toothless punch was proposed and studied. A test-piece with clear tooth profile, full filling, no folding, and no cracking was obtained in the experiment, and the results were basically consistent with the simulation results.
This paper aims to realize spur gears precision forming and overcome the deficiencies of traditional processes such as large forming force and complex mold structure. Two kinds of improved forming processes were proposed based on the existing spur gears forming of two-way upsetting-extrusion with tooth shape punch. The influence of friction on load under different forming processes was analyzed. The numerical simulation study of three kinds of forming processes was carried out by using the finite element simulation software DEFORM-3 D. It was proved that forming spur gears with toothless punch was superior to that with tooth shape punch in load and die structure, in which the load value of upper and lower punch of two-way upsetting-extrusion with toothless punch was decreased by about 55% compared with that with tooth shape punch. The load values of upper and lower punch of two-way upsetting-extrusion with toothless punch were decreased by about 50% and 38% compared with that with asymmetrical punch, suggesting that the manufacture of toothless punch is easier and with higher strength than tooth shape punch. The maximum effective-stress of the new process was the smallest among the three schemes, and the change was normal with no destructive phenomenon. Thus an optimized two-way upsetting-extruding precision forming process with toothless punch was proposed and studied. A test-piece with clear tooth profile, full filling, no folding, and no cracking was obtained in the experiment, and the results were basically consistent with the simulation results.
引文
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[5] 刘丹,刘华,王伟钦,等.直齿圆柱齿轮冷挤压可控运动凹模成形工艺[J].锻压技术,2016,41(9):84-87.LIU Dan,LIU hua,WANG Weiqin,et al.Forming technology of controlled movable die of spur gear in extrusion [J].Forging & Stamping Technology,2016,41(9):84-87.
[6] 孙红星,刘百宣,王伟钦,等.直齿圆柱齿轮双向挤镦均匀成形工艺研究[J].热加工工艺,2013,42(17):1-4.SUN Hongxing,LIU Baixuan,WANG Weiqin,et al.Study on two way extrusion upsetting uniform forming process of spur gear [J].Hot Working Technology,2013,42(17):1-4.
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[8] 陈跃男,吕兆波.直齿圆柱齿轮径向挤压成形及有限元分析[J].模具工业,2017,43(11):13-17.CENG Yuenan,Lü Zhaobo.Radial extrusion forming of cylindrical gear with straight-toothed and the finite element analysis[J].Die & Mould Industry,2017,43(11):13-17.DOI:10.16787/j.cnki.1001-2168.dmi.2017.11.003
[9] 李锦.直齿圆柱齿轮滚轧成形工艺数值模拟及实验研究[D].济南:山东大学,2017.LI Jin.Numerical simulation and experimental research of spur cylindrical gear rolling[D].Jinan:Shandong University,2017.
[10] 陈春香.直齿圆柱齿轮滚轧成形实验装置设计与开发[D].济南:山东大学,2016.CHEN Chunxiang.Design and development of spur cylindrical gear roll forming experimental device[D].Jinan:Shandong University,2016.
[11] 冯文杰,冉力,夏泽雨,等.直齿圆柱齿轮冷挤压变过盈量组合凹模设计方法[J].锻压技术,2017,42(2):104-109.FENG Wenjie,RAN li,XIA Zeyu,et al.Design on changeable interference combined die of spur gear in cold extrusion [J].Forging & Stamping Technology,2017,42(2):104-109.DOI:10.13330/j.issn.1000-3940.2017.02.020
[12] 冉力.载重汽车用直齿圆柱齿轮冷挤压模具强度及寿命研究[D].重庆:重庆理工大学,2017.RAN Li.Research on strength and life of cold extrusion die for spur gear of truck [D].Chongqing:Chongqing University of Technology,2017.
[13] 曹金豆.直齿圆柱齿轮连续冷挤压工艺及模具技术研究[D].重庆:重庆大学,2016.CAO Jindou.Research on the continuous cold extrusion process and mold technology of spur gear[D].Chongqing:Chongqing University,2016.
[14] 田维,安喜梅,程旺军.大模数直齿圆柱齿轮精锻数值模拟及模具设计[J].重型机械,2016(2):70-73.TIAN Wei,AN Ximei,CHENG Wangjun.Numerical simulation and die design of big module spur gear for precision forging[J].Heavy Machinery,2016(2):70-73.DOI:10.13551/j.cnki.zxjxqk.2016.02.016
[15] 陈亚伟.直齿圆柱齿轮温塑性精成形[D].长春:吉林大学,2015.CHEN Yawei.The warm plastic precision farming of spur gear[D].Changchun:Jilin University,2015.
[16] KONDO K.Precision cold die forging of a ring gear by divided flow method[J] .International Journal of Machine Tools & Manufacture,1995 ,35(8):1105-1113.
[17] ZHANG Z M,ZHANG B H,LIANG L.Investigation of plastic forming process for spur gear [C]//Proceedings of 6th ICTP.Nuremberg:[s.n.],1999:799-802.
[18] STONE E R H,CAI J,HU Z M,et al.An exercise in cold ironing as the post-forging operation for net-shape manufacture [J].Journal of Materials Processing Technology,2003,135(2/3):278-283.
[19] 张宝红.高性能直齿圆柱齿轮开放成形研究[D].太原:中北大学,2005.ZHANG Baohong.Study on opened-die forming for high property spur gear[D].Taiyuan:North University of China,2005.
[20] DENG X,HUA L,HAN X,et al.Numerical and experimental investigation of cold rotary forging of a 20CrMnTi alloy spur bevel gear [J].Materials and Design,2001,32:1376-1389.
[2] DEAN T A.The net-shape forming of gears [J].Materials and Design,2000,21:271-278.
[3] 皇涛,陈拂晓,郭俊卿,等.直齿圆柱齿轮精锻工艺研究现状与发展趋势[J].热加工工艺,2009,38(13):110-114.HUANG Tao,CHEN Fuxiao,GUO Junqing,et al.Research status and development trends of precision forging process for spiral bevel gear[J].Hot Working Technology,2009,38(13):110-114.
[4] 谭险峰,刘霞,熊洪淼,等.圆柱直齿轮精锻成形工艺仿真及试验[J].塑性工程学报,2010,17(1):22-26.TAN Xianfeng,LIU Xia,XIONG Hongmiao,et al.Simulation and experimental research on the precision forging of spur gear[J].Journal of Plasticity Engineering,2010,17(1):22-26.
[5] 刘丹,刘华,王伟钦,等.直齿圆柱齿轮冷挤压可控运动凹模成形工艺[J].锻压技术,2016,41(9):84-87.LIU Dan,LIU hua,WANG Weiqin,et al.Forming technology of controlled movable die of spur gear in extrusion [J].Forging & Stamping Technology,2016,41(9):84-87.
[6] 孙红星,刘百宣,王伟钦,等.直齿圆柱齿轮双向挤镦均匀成形工艺研究[J].热加工工艺,2013,42(17):1-4.SUN Hongxing,LIU Baixuan,WANG Weiqin,et al.Study on two way extrusion upsetting uniform forming process of spur gear [J].Hot Working Technology,2013,42(17):1-4.
[7] JIANG Jinke,FANG Zongde.Design and analysis of modified cylindrical gears with a higher-order transmission error[J].Mechanism & Machine Theory,2015,88:141-152.
[8] 陈跃男,吕兆波.直齿圆柱齿轮径向挤压成形及有限元分析[J].模具工业,2017,43(11):13-17.CENG Yuenan,Lü Zhaobo.Radial extrusion forming of cylindrical gear with straight-toothed and the finite element analysis[J].Die & Mould Industry,2017,43(11):13-17.DOI:10.16787/j.cnki.1001-2168.dmi.2017.11.003
[9] 李锦.直齿圆柱齿轮滚轧成形工艺数值模拟及实验研究[D].济南:山东大学,2017.LI Jin.Numerical simulation and experimental research of spur cylindrical gear rolling[D].Jinan:Shandong University,2017.
[10] 陈春香.直齿圆柱齿轮滚轧成形实验装置设计与开发[D].济南:山东大学,2016.CHEN Chunxiang.Design and development of spur cylindrical gear roll forming experimental device[D].Jinan:Shandong University,2016.
[11] 冯文杰,冉力,夏泽雨,等.直齿圆柱齿轮冷挤压变过盈量组合凹模设计方法[J].锻压技术,2017,42(2):104-109.FENG Wenjie,RAN li,XIA Zeyu,et al.Design on changeable interference combined die of spur gear in cold extrusion [J].Forging & Stamping Technology,2017,42(2):104-109.DOI:10.13330/j.issn.1000-3940.2017.02.020
[12] 冉力.载重汽车用直齿圆柱齿轮冷挤压模具强度及寿命研究[D].重庆:重庆理工大学,2017.RAN Li.Research on strength and life of cold extrusion die for spur gear of truck [D].Chongqing:Chongqing University of Technology,2017.
[13] 曹金豆.直齿圆柱齿轮连续冷挤压工艺及模具技术研究[D].重庆:重庆大学,2016.CAO Jindou.Research on the continuous cold extrusion process and mold technology of spur gear[D].Chongqing:Chongqing University,2016.
[14] 田维,安喜梅,程旺军.大模数直齿圆柱齿轮精锻数值模拟及模具设计[J].重型机械,2016(2):70-73.TIAN Wei,AN Ximei,CHENG Wangjun.Numerical simulation and die design of big module spur gear for precision forging[J].Heavy Machinery,2016(2):70-73.DOI:10.13551/j.cnki.zxjxqk.2016.02.016
[15] 陈亚伟.直齿圆柱齿轮温塑性精成形[D].长春:吉林大学,2015.CHEN Yawei.The warm plastic precision farming of spur gear[D].Changchun:Jilin University,2015.
[16] KONDO K.Precision cold die forging of a ring gear by divided flow method[J] .International Journal of Machine Tools & Manufacture,1995 ,35(8):1105-1113.
[17] ZHANG Z M,ZHANG B H,LIANG L.Investigation of plastic forming process for spur gear [C]//Proceedings of 6th ICTP.Nuremberg:[s.n.],1999:799-802.
[18] STONE E R H,CAI J,HU Z M,et al.An exercise in cold ironing as the post-forging operation for net-shape manufacture [J].Journal of Materials Processing Technology,2003,135(2/3):278-283.
[19] 张宝红.高性能直齿圆柱齿轮开放成形研究[D].太原:中北大学,2005.ZHANG Baohong.Study on opened-die forming for high property spur gear[D].Taiyuan:North University of China,2005.
[20] DENG X,HUA L,HAN X,et al.Numerical and experimental investigation of cold rotary forging of a 20CrMnTi alloy spur bevel gear [J].Materials and Design,2001,32:1376-1389.