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提出带肋板齿轮坯开式模锻和闭式模锻两种热精锻成形工艺方案,借助有限元分析软件模拟了两种工艺方案下齿轮坯的成形过程,分析比较了两种方案中的金属流动规律。仿真结果显示:采用开式模锻,肋板充填不饱满,成形载荷大;采用闭式模锻,零件成形质量较高,成形载荷较小。导致开式模锻成形载荷大并且肋板充填不饱满的原因为:成形中后期充填肋板的金属流动阻力增加,金属径向流动加剧并形成较大飞边,随着上模下压,飞边变形消耗滑块能量,并增加了与模具的接触面积,导致成形力急剧增加而模具型腔充填不饱满。工艺实验表明,其结果与数值模拟相吻合。
Two kinds of hot forging process schemes of open die forging and closed die forging with ribbed plate are proposed. The forming process of gear blanks under two kinds of technological schemes is simulated by finite element analysis software. The two schemes are compared and analyzed Metal flow rule. The simulation results show that: the open die forging, rib filling is not full, the forming load is large; the use of closed die forging, forming a higher quality parts, forming a smaller load. The reason for the large load of open die forging and the insufficient filling of the ribs is as follows: the flow resistance of the metal filled with the ribs in the middle and later stages of forming is increased, the radial flow of the metal is aggravated and a large flash is formed, Side deformation consumes the slider energy, and increases the contact area with the mold, resulting in a sharp increase in forming force and the mold cavity filling is not full. Process experiments show that the results are consistent with numerical simulation.