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为阐明直齿圆柱齿轮两步精密成形新工艺“半隆埂预成形+劈挤终成形”变形过程中的金属流动规律,以模数为4、齿数为12、齿厚为30 mm的实体齿轮为研究对象,运用Deform-3D数值模拟软件的点追踪功能,进行正、反向追踪观察分析。结果表明:预成形过程中,坯料发生整体镦粗变形,径向半隆埂状起伏侧面容易获得;终成形过程中,沿周径向宽度不大的范围内发生连续局部变形,齿槽空间原有金属被推向两侧,齿槽底面来自坯料非表层,齿顶金属由预成形的齿埂侧面转移而来,轮齿及齿槽金属均发生了较明显的轴向位移,且齿顶位移大于齿根位移,后期,部分表层金属作为余料被剥离,既为实际应用提供了工艺补偿环节,又去除了容易脱碳的表层。该工艺借助于构造不太复杂的模具和简单的模具动作,得到了清晰、饱满的轮齿及齿槽。
In order to clarify the metal flow law during the two-step precision forming process of spur gear, such as “semi-cylindrical 埂 pre-forming + final forming”, with a modulus of 4, a number of teeth of 12 and a thickness of 30 mm Of the solid gear as the research object, the use of Deform-3D numerical simulation software point tracking function, the positive and negative tracking observation and analysis. The results show that during the process of preforming, the billet as a whole is upset and deformed, and the undulating lateral surface of the radial half-silky billet is easy to obtain. In the final forming process, continuous local deformation takes place within the range of small circumferential radial width. The original metal is pushed to the both sides, the bottom of the tooth groove is from the non-surface of the blank, the addendum metal is transferred from the side of the preformed denture, and the tooth and the alveolar metal have obvious axial displacement, Displacement is greater than the tooth root displacement, the late part of the surface layer of metal as the remaining material was stripped, not only for the practical application of the process of compensation links, but also remove the easy decarburization of the surface. The process by virtue of the construction of less complex mold and simple mold action, get a clear, full of gear and tooth groove.