锻压技术

某档位齿轮坯精锻成形模具结构参数的数值模拟分析及优化

英文标题：Numerical simulation analysis and optimization on precision forging die structure parameters for a gear blank

作者：张辉李伟潘爱琼周杰

单位：郑州科技学院重庆大学

分类号：TG316.3

出版年,卷(期):页码：2017,42(5):181-184

摘要：

针对某档位齿轮坯在闭式精锻成形过程中径向筋部出现的充填不饱满和折叠的缺陷，为了优化金属的流动性，改善筋部的填充情况，获得性能优良的合格锻件，运用正交实验和有限元结合的方法，分析了模具筋部拔模斜度α、圆角半径R对成形过程的影响，得出了极限模具结构参数图。分析了不同区域模具结构参数对成形质量的影响，确定在区域D中的参数条件下，锻件无明显的充不满和折叠缺陷，并优选拔模斜度为1.3°、圆角半径为3 mm进行了实际生产验证。研究结果表明：锻件质量良好，筋部端面平整，底部无折叠缺陷，实际锻件与数值模拟结果相吻合。

For the incomplete filling and folding defects occured in the radial rib of a gear blank in closed-die precision forging, in order to optimize metal mobility, improve the filling condition and get qualified forgings，the influences of drafting angle α and fillet radius R on forging process were analyzed by combining orthogonal experiment with finite element method, and the critical diagram of mold structure was given. Then, the influences of different structural parameters on the forming quality were analyzed, and forging parts were without significant incomplete filling and folding defects under the parameters conditions in the zone D. At last，the actual production with the draft angle of 1.3° and the fillet radius of 3 mm was validated. The results show that the forgings are in good quality with flat rib face and are free of folding defects in the bottom. The actual forging part is consistent with the numerical simulation results.

基金项目：

科技型中小企业技术创新基金资助项目(101010 620080022)

张辉（1985-），男，硕士，工程师

参考文献：

［1］王华君，夏巨谌，孙世为，等. 从动螺旋伞齿轮精锻成形数值模拟和实验研究[J]. 塑性工程学报，2005，12(3)：14-17.Wang H J, Xia J C, Sun S W, et al. Numerical simulation and experimental study of precision forming in passive spiral bevel gear [J]. Journal of Plasticity Engineering, 2005, 12(3): 14-17.
［2］李天兴，张迅雷，傅建中，等. 轿车用齿坯精锻工艺参数与模具结构对金属流线的影响[J]. 机械传动，2015，(10)：154-157.Li T X, Zhang X L, Fu J Z, et al. Influence of the technological parameter and die structure on metal flow line for precision forging car gear blank[J].Journal of Mechanical Transmission, 2015, (10):154-157.
［3］胡亚民，夏华，张鈺成. 摩托车带爪齿轮坯的精锻成形数值模拟与工艺研究[J]. 塑性工程学报，2006，13(2)：48-50.Hu Y M, Xia H，Zhang Y C. The numerical simulation and process study of precise forging for finger gear blank of motorbike [J]. Journal of Plasticity Engineering, 2006, 13(2): 48-50.
［4］孙建辉，谢瑞，薛克敏，等. 带轴齿轮坯闭式精锻成形数值模拟与实验研究[J]. 精密成形工程，2016，8(5)：137-141.Sun J H, Xie R, Xue K M, et al. Numerical simulation and experimental study on closed precision-forging for shaft gear billet [J]. Journal of Netshape Forming Engineering,2016, 8(5): 137-141.
［5］罗善明，房媛.弧齿锥齿轮精锻成形工艺的数值模拟[J].中国机械工程，2009，20（4）：485-487.Luo S M, Fang Y. Numerical simulation on precision forging of spiral bevel gear [J]. China Mechanical Engineering, 2009, 20（4）: 485-487.
［6］冯玮.圆柱螺旋齿轮冷精锻成型的三维刚塑性有限元模拟[J]. 热加工工艺，2010，39(11)：91-96．Feng W. 3D rigid plastic finite element simulation of precision cold forming of helical gear[J].Hot Working Technology, 2010, 39(11): 91-96.
［7］潘俊杰，张辉，李军超，等. 基于数值模拟评价刮板锻造工艺的研究[J]. 热加工工艺, 2012，41(5)：112-114.Pan J J, Zhang H，Li J C, et al. Research on forging process of scraper based on numerical simulation [J]. Hot Working Technology, 2012，41(5)：112-114.
［8］王广春，赵国群，夏世升.直齿轮精锻成形新工艺及试验研究[J].机械工程学报，2005，41（2）：123-126.Wang G C, Zhao G Q, Xia S S. New precision forging process and experimental study on spur gears [J]. Journal of Mechanical Engineering，2005, 41(2): 123-126.
［9］贾艳楠，吴耀金，薛勇，等. 镁合金厚壁锥壳构件内环筋挤压成形金属充填规律研究[J]. 锻压技术，2015，40(2)：93-97.Jia Y N，Wu Y J，Xue Y, et al. Research on metal filling regularity of inner annular rib extrusion forming in the thick conical shell of magnesium alloy parts [J]. Forging & Stamping Technology, 2015, 40(2): 93-97.
［10］张辉.档位齿轮坯精锻成形的数值模拟研究及工艺优化[D].重庆：重庆大学，2013.Zhang H. Design and Optimization of the Precision Forging Process for Shifting Gear Blank by the Numerical Simulation Method [D]. Chongqing: Chongqing University, 2013.

服务与反馈：

【本网站尚未开通全文下载服务】【加入收藏】