锻压技术

斜齿圆柱齿轮一步精密成形数值模拟

英文标题：Numerical simulation on a new precision forming of helical cylindrical gear with one step

作者：陈家张如华郑志强龙启博陈凡荟

单位：南昌大学

关键词：斜齿圆柱齿轮精密成形凹模结构优化数值模拟扩腔空间结构参数

分类号：TG316

出版年,卷(期):页码：2016,41(9):13-17

摘要：

探索一种集成了分流成形与推过整形优点的一步法斜齿圆柱齿轮精密成形新工艺，以模数为4 mm、齿数为12

、螺旋角为14°、齿宽为29 mm的斜齿圆柱齿轮为研究对象，设计了成形模具，采用Deform-3D软件对成形过

程进行模拟研究。首先进行了新工艺的成形力分析，之后，采用控制变量法探索了齿宽方向扩腔范围b、扩

腔斜角α和齿高方向扩腔范围h这3个扩腔空间结构参数对齿轮下角隅充满效果及成形力的影响。分析结果表

明，新工艺能明显降低成形力。即金属分流量的多少决定着成形效果，金属分流量由b、α和h三个参数组合

决定，三者影响规律类似。即当其他条件一定时，若b（或α亦或h）过小，则成形力很大，分流量不足，导

致下角隅填充不饱满；反之，虽然成形力较小，能得到完整齿形，但分流量过多，容易产生废料；当b、α

和h取合理组合值：b为16 mm，α为10°和h为3 mm时，成形力适中且分流量合理，可以得到无废料的完整齿

形。

It was studied the one-step forming method of helical cylindrical gear which combined the

advantages from the divided forming and the push sizing. For the helical gear with modulus 4

mm, teeth numbers 12, angle of helix 14° and teeth width 29 mm, the structure of die was

designed and the whole forming process was analyzed by Deform-3D numerical simulation

software. Firstly, the forming force was analyzed, and then the influences of structure

parameters of the expanding cavity such as b in tooth width direction, bevel angle α, and h

in tooth height direction on filling effect at the bottom corner and the forming force were

discussed by the method of control variables. The results show that the forming load of the

new method is obviously reduced. Thus, the forming effect dependent on the amount of divided

metal, which is controlled a combination of b，α and h. However, the effects of their changes

are similar. When other conditions are kept fixed, a smaller b (or α, or h) brings a larger

forming force with insufficient differential throttling resulted in inadequate corner fulling.

On the contrary, even though the forming force is small to form teeth completely, the divided

metal is overmuch to produce the waste. Only a suitable combination with b 16 mm,α 10° and h

3 mm is acceptable. In conclusion with suitable divided metal and reasonable forming force, a

fulfilled corner gear without waste can be obtained.

基金项目：

江西省教育厅科技计划项目（GJJ13192）；江西省发明专利研发引导项目（20143BBM26105）

陈家（1990-），男，硕士研究生

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