螺旋伞齿轮精锻成形的研究.pdf

摘要螺旋伞齿轮广泛应用于汽车、拖拉机、坦克等行走机械的驱动桥上,需求量很大,而目前仍采用传统的切削工艺进行加工,材料利用率低,产品质量欠佳,难以满足工业快速发展对齿轮高性能的要求。因此,为提高生产效率,改善产品质量,开发一种螺旋伞齿轮成形的新工艺是非常必要的。本文在螺旋伞齿轮开式模锻成形工艺的基础上,对螺旋伞齿轮精锻成形新工艺、无飞边精锻模具设计及成形工艺参数等问题进行了研究。新型精锻模具采用浮动凹模结构,生产的锻件无飞边,提高了材料的利用率。采用主应力和上限联合法及变形功法分别建立求解螺旋伞齿轮开式模锻和无飞边模锻锻压成形力的数学模型,并求得了锻压成形力。利用UG软件对模具工作部分进行三维造型,并运用数值模拟软件DEFORM-3D对螺旋伞齿轮无飞边精锻成形过程进行仿真。研究了成形过程中金属的流动规律及速度场、应变场、应力场、温度场在成形不同阶段的分布情况,并得到了载荷一行程曲线,其成形载荷与理论计算结果非常吻合。对成形工艺参数进行了优化,并利用工艺实验对其进行了验证。实验结果表明,在始锻温度为1150。C,压力机平均工作速度为200mm/s,润滑条件良好时,螺旋伞齿轮成形良好,齿形饱满,齿根部分过度平滑,无塌陷、折叠等缺陷,使用效果很好。模具结构紧凑,工作稳定可靠,使用寿命长。本文所用的锻模设计、计算机辅助设计、数值模拟等相关方法具有一定的通用性,可为其他齿轮类零件的锻造成形分析、模具设计提供参考。关键词:螺旋伞齿轮精密模锻锻压成形力数值模拟工艺实验 Abstract Spiral bevel gear is ingreat demand which apply extensively tothedriveaxleofvehicle such asautomobile,tractor,tank and present,traditional cutting technology isstilladopted in theproduction ofspiral low production efficiency andbadqualityofproduct,this technology ishard to meet the rapidly growing industry requires ofthe gear withhigh itisextremely essential to develop anew formingtechnology forspiral bevel gear withthepurpose ofimprove productionefficiency andquality of onopen—die fo晤ng process ofspiral bevel gear,thispaper conduct research onnew formingtechnology,closed forging diedesignandprocess parameters. Floating cavity diemechanism wasadopted onthe new forging die,theproduct withoutburrs Wasachieved,the materialutilization work method,Slap method and Upper boundary method bined toestablish amathematical model pute the deforming force ofopen-die forging process andclosed forging process ofspiral bevel gear,the value ofdeforming forceWasobtained. UG makes the die3D moulding andDEFORM-3D simulatestheprocess on precision forging ofspiral bevel metalflowing lawwith distribution ofvelocity field,strainfield,stress fieldandtemperature field atdifferentstages offorming werediscussed,the load-strokecurve was obtained,thedeforming force istally well