锻压技术

大型齿轮毛坯锻造及热处理工艺改进

英文标题：Technology improvement on forging and heat treatment of large gear blank

作者：张毅峰王雷刚吴君三周云鹤胡振奇

分类号：TG316

出版年,卷(期):页码：2010,35(6):6-11

摘要：

大型齿轮毛坯生产技术难度大，锻造时成形力过大、金属局部充不满，热处理时常规材料淬透层不深、台阶过渡处易开裂。本文分析了大型齿轮毛坯锻造过程中的金属流动规律，提出了基于分流减压原理的毛坯预成形新工艺，可减小成形力约30%。分流减压槽的合理设计能使轮毂、轮缘同时充填饱满。为了进一步改善金属轴向流动不均匀，采用了不对称的上下模腔设计方法；在分析了组织性能关系的基础上，采用高淬透性材料，并提出了正火+分级淬火的热处理工艺，防止齿轮毛坯开裂变形且晶粒度可达7级。通过有限元热力耦合数值模拟、试验验证、微观组织观察和性能分析，验证了本文中锻造与热处理工艺方案的可行性，获得了良好效果，满足了用户的需求。

Large gear blank production technology is difficult.The excessive deformation force and unsuccessful local filling are the main limitation of forging, and conventional materials with no deep hardening layer and easy step transition cracking are the main defects of heat treatment. Analysis of metal flow rule in the large gear blank forging process, the novel technology which based on distributary and decompression principle were proposed, which usefully reduced deformation force by about 30%. The reasonable design of distributary and decompression groove could make wheel hub and rim fill simultaneously. To improve the non\|uniform flow, the novel technology was further improved with unsymmetrical punch. Based on the analysis of microstructure and prosperities, high harden ability materials heat treatment technology of normalizing and stepped quenching was proposed, which can avoid cracking and deformation. Grain size reaches grade seven. The novel technology which meets the needs of users was further validated by numerical simulation of coupled thermo\|mechanical, experimental verification, microstructure observation and performance analysis.

基金项目：

江苏省研究生工作站项目；江苏大学科技创新团队项目

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