锻压技术

采用下角隅扩腔凹模成形直/斜齿柱形齿轮

英文标题：Spur/helical gear precision forming by expanding die cavity at bottom corner

作者：张如华龙启博王磊尹燕黄智松陈家

单位：南昌大学

关键词：闭式模锻直/斜齿柱形齿轮凹模扩腔空间分流成形推过整形

分类号：TG316

出版年,卷(期):页码：2016,41(9):23-27

摘要：

为实现直/斜齿柱形齿轮一步精密成形，并克服现有工艺存在的轮齿角隅欠饱满、成形力大、模具结构复杂

、对设备动作要求复杂等一系列不足，提出了一种将成形过程划分为镦压、顶出两个阶段，在凹模下角隅设

置扩腔空间的闭式模锻新工艺。以模数为4、齿数为12、齿宽为30 mm的实体正齿轮为主要研究对象，采用扩

腔空间几何参数优化组合的凹模，借助于Deform软件flow net功能，从变形体外观和内部最能反映上、下角

隅填充效果的两个纬面，观察分析了新工艺两个阶段过程中金属的填充情况，以及与传统闭式模锻变形力对

比情况。结果表明，镦压结束时上角隅填充良好，下角隅虽然欠充满，但仍有合适体积流入扩腔空间；相对

传统闭式模锻，镦压力明显减小。顶出阶段时在扩腔空间倾斜侧壁作用下，流入扩腔空间的体积向下角隅回

流，实现下角隅填充。新工艺集成了分流成形与推过整形方法优点，模具结构及设备动作要求简单，新工艺

效果得到物理模拟实验验证。

In order to realize the spur/helical gear precision forming by one step and overcome a series

of deficiencies such as less full tooth corner, big forming force, complex mold structure,

complex motion requirements of equipment in the current process, a new forming technology of

no-flash die forging was put forward. The forming process was divided into upsetting and

ejection stages, and applied in the expanding die cavity at die bottom corner. For the entity

spur gear with modulus 4, teeth numbers 12 and teeth width 30 mm, the process of metal filling

at two stages and the comparison with conventional no-flash die forging were observed and

analyzed by flow net function of the Deform software, which used the expanding die cavity with

optimized geometrical parameters from two weft surfaces reflecting the fill effects of top and

bottom corners the best from the exterior and interior. The result shows that when upsetting

is over, the top corner fills well, while the bottom corner is not full and the proper volume

flows into the expanding cavity. Therefore, compared with conventional no-flash die forging,

the upsetting force obviously drops. At the ejection stage, under the influence of slanted

side, the volume that previously flowing into the expanding cavity flows back to the bottom

corner, and the bottom corner is filled. New technology combines the advantages of divided

flow forming and push sizing, and simplifies the mould structure and motion requirements of

the equipment. Furthermore, the effect of new technology is verified by physical experiment.

基金项目：

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

张如华（1958-），男，硕士，教授

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