摘要
目前，齿轮的主要加工方式仍然是切削加工或者先热锻，后机加工，这导致生产成本高昂，效率低下。与传统成形方法加工的齿轮相比，精锻齿轮具有无飞边、无后续机加工等优点，从而节省原材料和能源耗费，降低成本和提高生产率，具有显著的经济效益。近年来，齿轮精锻技术的研究越来越活跃。作为国家十五“863”计划，本文针对直齿圆柱齿轮精锻工艺相关技术进行了研究。
本文采用数值模拟和试验研究相结合的手段进行研究。利用VBA完成了渐开线齿轮几何造型和模型建立，解决了在AutoCAD2000下不能绘制渐开线齿形的问题；介绍了刚塑性有限元法基本原理，并探讨了迭代收敛、网格重分等几个关键问题；对浮动凹模和中空分流等工艺进行了数值模拟和试验研究，分析了影响径向充填的关键因素，尤其是摩擦系数对成形的影响，提出了改善充填状况的方法，提出了均衡成形思想。
针对DEFORM-3D软件后处理功能的不足，研究了数值模拟后处理方法，得到了工件的边界曲线，为进一步的高精度模拟分析提供了手段；比较了当前精锻齿形修形方法，用数值模拟和试验相结合的手段，分析了精锻过程中各环节对齿形精度的影响，用弹性有限元法模拟了模具的弹性受力变形和齿轮出模弹性回复对齿形精度的影响，得到了模具齿形的变化规律，并提出了全新的修形方案；最后，采用本文的工艺手段和精度控制措施，进行了一系列齿轮精锻试验，并进行了小批量的生
摘要
产。
本文最后对成形齿轮进行了精确测量，结果显示，成形齿
轮精度达到国家8级水平。本文的研究工作为最终863科研任
务的完成奠定了基础。
Spur gears are mainly manufactured by metal cutting or by a combination of conventional hot forging with machining, which results in high production cost and much manufacturing time. Precision forging of gears has a lot of advantages compared to conventional gear shaping, because it allows the manufacture of gear parts without flash and consequently without the need for subsequent machining operations. Therefore, the implementation of such a technology is capable of providing important economic benefits in terms of raw material and energy savings, and also achieve considerable cost saving due to higher productivity. In recent years, the development of precision gear forging process has been an area of increasing activity. As one of the 863 Programs, this thesis aims at a detailed investigation of cold precision forging of spur gears
The study in this thesis were performed by the combination with numerical simulations and experiments. Firstly, the CAGB of spur gears using VBA was realized, which solved the problem of tooth profile drawing in AutoCAD2000. Then, the rigid-plastic FEM was introduced and several important problems in simulation such as convergency and remeshing were discussed. And plenty of simulations and experiments have been carried out to analyze the
various processes of gear forging, and several factors such as the friction factor, which had great influence on the radial flow of the material, have also been investigated. As a result, the equilibrium filling concept has been put forward.
To make up for the deficiency of the graphical display in post-process of DEFORM, a new method that can automatically obtain the profile of the object has been achieved, which made it possible to catch the slightly deformation of the die. Additionally, lots of simulations and experiments were done to analyze the different factors influencing the gear tooth accuracy, such as the elastic expansion of die and the spring-back of the forged gears. Consequently the deformation mechanism of the closed die has been obtained and a new method of tooth profile modification was put forward. At last, with the improved forming process and accuracy control operation in this thesis, series of experiments of precision gear forging have been implemented.
The result of the measure about the forged gear is satisfied.
The accuracy has reached class 8~(th) according to GB10095, and the effort in this thesis has provided a basis for the accomplishment of the 863 Program.
引文
[1] R Kopp, Current Development Trends in Metal Forming Technology, J. Mater. Process, Technol, 1996, 60:1～10
[2] V Magard, Cold Forging of Net or Near-net-shape Components, J.Mater. Process. Technol, 1992, 35:429～433
[3] 冯冲前，浮动凹模镦挤直齿圆柱齿轮成形原理及工艺研究，燕山大学硕士论文，2001：1～10．
[4] 李敏贤、闵乃燕、安桂华、陈世兴，精密成形技术发展前沿，中国机械工程，2000．2，Vol．11，No．1-2：183～186
[5] 皇甫骅、李社钊等，先进制造技术和精密成形技术．汽车工艺与材料，1996，No12：1～4
[6] 陈贤杰、雷源忠、李敏贤，先进制造技术在我国的发展，先进制造技术发展战略学术研讨会论文集，上海1998：81～85
[7] Richard Douglas, David Kuhlmann, Guidelines for precision hot forging with applications, Materials Processing Technology,2000,98:182～188
[8] N.R.Chitkara, M.A.Bhutta, Near-net shape forging of spur gear forms: an analysis and some experiments Int. J.Mech. Sci. 1996,Vol.38,No.8～9:819～916
[9] 孙宗强、田福祥，直齿圆柱齿轮精锻研究的现状及发展趋势，青岛建筑工程学院学报，2000，Vol．21，No．4：98～102
[10] M.L.Alves, J.M.C.Rodrigues, P.A.F. Martins, Cold forging of gears: experimental and theoretical investigation, Finite elements in analysis and design,2001,No.37:549～558
[11] 《齿轮制造手册》编委会，齿轮制造手册，1998，第一版，机械工业出版社
[12] 李洪波、吕玫、骆俊廷，精锻齿轮弹性回复的理论分析和
有限元模拟，模具技术，2003，No．1：7～9
[13] Pneumatic mechanical forging, state of the Art, lst Int. Conf. HEF, Estates Park, June 1967
[14] A. R. D. A. bdul-Rahman and T. A. Dean, Production considerations for the high speed forming of spur gear forms, Proc, M.T.D. R, 1987, 14th, Conf:807
[15] A. R. D. A. bdul-Rahman and T.A. Dean, The quality of hot forged spur gears, Part1:Mechnical and metallurgical properties. Int. J.M.T.D.R, 1987, 21th, 109
[16] A.R.D.A.bdul-Rahman and T.A.Dean, The quality of hot forged spur gears,Part2: tooth form accuracy. Int, J.MTDR, 1987, 21th, 128
[17] 蒋鹏、谢谈等，国内精密锻造技术的近期状况，锻压技术，2002，No．3：12～15
[18] 蔡利，未来十年国内精密锻造技术展望，金属成形工艺，2002，Vol．20，No．3：55～58
[19] 孟凡中，弹塑性有限变形理论和有限元方法，清华大学出版社，1985，第一版
[20] 董湘怀，材料成形计算机模拟，机械工业出版社，2002，第一版
[21] 孙红星，汽车转向齿条的冷精锻成形工艺及其数值模拟，西安交通大学硕士学位论文，2001
[22] 诸文俊、胡亚民、张驰，浅谈国内外齿轮精锻工艺，1991，Vol．9No．1：60～64
[23] 陈泽中、林治平等，直齿圆柱齿轮精锻技术的研究进展，金属成形工艺，1999，Vol．17．No．5：1～3
[24] 张宝红、张治民、马宏强，直齿轮径向导流成形工艺研究，山西机械，1998，No．2：4～6
[25] Abdul N A and Dean T A.An Analysis of the forging of the
forging of spur gear forms. Int .J. Math .Tool Des.Res, 1986,26(2): 113～123
[26] Choi J C.A study on the forging of spur gears,Int. J.Mech. Sci.,1996,38(12):1331～1340
[27] 寇淑清、杨慎华、夏晓峰，高精度直齿圆柱齿轮冷锻成形加工方法的研究，锻压技术，2000，No．5：10～13
[28] 冯宝伟、胡亚民，国内外精密塑性成性技术的新动向，金属成形工艺，Vol．17．No．2．1999：7～9
[29] 李延龄，六面体有限元网格自动剖分技术研究，郑州机械研究所硕士学位论文，2002
[30] 寇淑清、杨慎华、黄良驹、付沛福，直齿圆柱齿轮净成形技术研究，热加式工工艺，1999，Vol．5：29～31
[31] 卢险锋，冷锻工艺与模具，机械工业出版社，1999，第一版
[32] Dean T A Progress in Net-Shape Forging[A]. Advanced Technology of Plasticity[C].Beij ing: 1993:1031～1041
[33] 寇淑清，三维复杂锻造过程数值模拟以及直齿轮冷精锻成形研究，吉林工业大学博士论文，1998
[34] Magard V. Cold Forging of Net or Near-Net-Shape components[J] J. Mater. Process Technol. 1992,35:429～433
[35] 谭险峰，带轮毂直齿圆柱齿轮精锻的变形分析，金属成形工艺，1998，16(1)：31～32
[36] 林治平，直齿圆柱齿轮精锻工艺方案的研究锻压技术，1999，No．2：9～12
[37] 王玉柱，直齿圆柱齿轮冷精锻上限分析及实用化工艺研究吉林工业大学硕士学位论文，1997
[38] [日]大泽佳狼，日本锻造行业现状，锻压技术，1995，No．1：3～5
[39] 寇淑清、杨慎华、黄良驹、傅沛福，用约束分流法冷锻成
形高精度直齿圆柱齿轮，吉林工业大学自然科学学报，2000，Vol．30，No．2：19～23
[40] D Y Yang, PhD, N K Lee, Ms, J H Yoon, PhD. A three-dimensional rigid-plastic finite element analysis of spur gear forging using the modular remeshing technique. Proc Instn Mech Engrs Vol.205
[41] Masayoshi Ogura(1),Kazuyoshi Kondo(2),Precision Forging of Helical Gears Utilizing Divided-flow Method. The Seventh Asia Symposium on Precision Forging, Oct,2000:22～25
[42] 李洪波、高新、吕梅，圆柱直齿轮浮动式精锻模设计，模具工业，1995，No．9：43～45
[43] 刘庆斌、孙胜、刘伟强、栾贻国，直齿轮成形数值模拟及实验研究，金属成形工艺，1995，Vol．13．No1：34～38
[44] J.C.Choia, Y. choib Precision forging of spur gears with inside relief, International Journal of Machine Tools &Manufacture 1999, 39:1575～1588.
[45] 赵国群、王同海、赵振铎，金属成形有限元灵敏度分析理论及模具优化设计方法研究，43～46
[46] 江雄心、林治平，体积成形三维有限元模拟的进展，3～8
[47] V.M.Drecun and T.A.Dean, A parametric cad program for die sets for precision forging spur gears, Int. I.Mach.Tools Manufacture 1991, Vol.31.No.2:183～191
[48] 田福祥、孙宗强、刘晓玲、付志刚，新型内齿轮精锻模结构设计及参数计算，模具工业，2000，No．4：38～41
[49] 田福祥、孙宗强、付志刚，新型圆柱齿轮精锻模，模具工业，2000，No．7：49～62
[50] 谭险峰、林治平，带轮毂直齿圆柱齿轮精锻的变形分析，金属成形工艺，1998，Vol．16．No1：31-33
[51] D Y Yang, PhD and J.H.Yoon, PhD, Computer-aided
numerical analysis and design for cold extrusion of a spur gear, Proc Instn Mech Engrs Vol.204.
[52] 田福祥，直齿圆柱齿轮精锻模具齿形设计，锻压技术，1998 No．2：57～59
[53] 寇淑清、傅沛福、杨慎华、黄良驹，齿轮精锻成形三维弹塑性有限元数值模拟，哈尔滨工业大学学报，2000，Vol．32 No．4：68～71
[54] 林治平、陶泽球，用实心坯料冲挤精锻直齿圆柱齿轮的计算机模拟，塑性工程学报，mar，2000，Vol．7 No．1：50～54
[55] 北京机电研究所，锻压，机械工业出版社，2002年第一版
[56] 韩秀全，直齿圆柱齿轮冷精锻模具弹性变形有限元分析，吉林工业大学硕士学位论文，1999
[57] 王玉国，直齿圆柱齿轮冷精锻上限分析及实用化工艺研究，吉林工业大学硕士学位论文，1997
[58] 胡忠民，齿轮精密锻造技术的发展，2003
[59] K.Kondo K, Developments of new precision cold die forging processes, Advanced Technology of Plasticity-Proc, Of lst, 1984:701～709
[60] C.Tuncer and T.A.Dean, Die Design Alternatives for Precision Forging Hollow Parts, Int, J.Mach. Tools, Vol.27,No1:65～76
[61] C.Tuncer and T.A.Dean, Precision Forging Hollow Parts in Novel Dies, J.of Mech. Working Technology, 1988,16,39～50.
[62] Kyoichi OHGA, Kazuyoshi Kondo: Research on Precision Die Forging Utilizing Divided Flow (First Report, Theoretical analysis of process utilizing flow relief-axis and relief- hole), Bulletin of JSME, 1982, Vol.25, No.209:1828～1835
[63] Kyoichi OHGA, Kazuyoshi Kondo: Research on Precision Die Forging Utilizing Divided Flow(Second Report, Experimental study of process utilizing flow relief-axis and relief-hole),
Bulletin of JSME, 1982,Vol.25,No.209:1836～1842
[64] Kyoichi OHGA, Kazuyoshi Kondo: Research on Precision Die Forging Utilizing Divided Flow(Third Report, Study on an optimum combination by "two step method" proposed), Bulletin of JSME, 1982,Vol.25,No.209:1843～1850
[65] Kyoichi OHGA, Kazuyoshi Kondo: Research on Precision Die Forging Utilizing Divided Flow(Forth Report, Influence of restricting a centripetal flow), Bulletin of JSME, 1983,Vol.26, No.218:1434～1441
[66] Kyoichi OHGA, Kazuyoshi Kondo: Research on Precision Die Forging Utilizing Divided Flow(Fifth Report, Application to actual machine parts), Bulletin of JSME, 1985,Vol.28,No.244: 2451～2459
[67] 周思柱，金属成形的三维有限元模拟系统的发展和展望，锻压技术，1998，No．4：46～50
[68] K.KONDO, T. JITSUNARI, K.OHGA, Investigations on Cold Forging of a gear Utilizing Divided Flow, Bulletin of JSME, 1985, Vol.28.No.244:2442～2450
[69] 谭险峰、林治平，直齿圆柱齿轮精锻模具设计，模具技术，2000，No．2：42～44
[70] 孙桓、傅则绍，机械原理，高等教育出版社，1989年第四版
[71] 林治平，锻压变形力的工程计算，机械工业出版社，1986年第一版
[72] K．Kondo，精密冷模锻新工艺的开发；世界塑性加工最新技术译文集，北京，机械工业出版社，1987：701～709
[73] 刘建生等，金属塑性加工有限元模拟技术与应用，冶金工业出版社，2003年第一版．
[74] 张琳娜，精度设计与质量控制基础，中国计量出版社，1997
年第一版