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分析了同步器齿环模锻成形过程的金属流动特点,针对同步器齿环模锻成形后花键附件齿顶存在裂口的问题,为改善金属的充模流动状态,提出将齿形的充填由金属的径向流动为主变为轴向镦挤流动为主的模式。应用刚塑性有限元理论及数值软件,对同步环的模锻过程进行了模拟,得出齿顶裂口的原因是齿顶金属充不满所致。通过加大环坯的内、外直径,改变了环坯在模具型腔中的定位,工艺改进有效的改善了齿形形成过程中金属的径、轴向流动状况。模拟结果显示,工艺改进后,花键上方齿顶成形饱满。批量生产后的产品检测未发现齿顶有裂口。
In order to improve the metal filling flow state, aiming at the problem of the metal gear flow in die forging process of synchronizer gear ring, Metal radial flow into the main axial upsetting flow-oriented mode. The rigid plastic finite element theory and the numerical software were used to simulate the swaging process of the synchronizing ring. The reason of the tooth crest was that the metal top filled with metal was not satisfied. By increasing the inner and outer diameter of the ring billet, the position of the billet in the mold cavity is changed. The process improvement effectively improves the diameter and axial flow of the metal in the tooth forming process. Simulation results show that, after the process improvement, the top of the spline is formed full of tooth tops. After the mass production of the product testing found no crest of the tooth.