锻压技术

车用齿轮轴零件精密成形工艺分析及数值模拟

英文标题：Precision forming process analysis and numerical simulation of automotive gear shaft parts

分类号：TG376.3

出版年,卷(期):页码：2017,42(12):68-74

摘要：

提出了两种车用齿轮轴零件的冷挤压成形工艺方案，即不带背压装置的方案1与带有背压装置的方案2，同时对带有背压装置的冷挤压模具进行了设计。利用Deform-3D分别建立了两种方案的有限元模型并进行了成形数值模拟。模拟结果表明：采用带有背压装置的方案2时，工件的等效应力、等效应变、损伤值及成形载荷的最大值均小于方案1，同时成形质量较好。方案2比方案1可节材22%，且成形载荷只有方案1的86%。对两种工艺方案分别进行了试验验证，验证结果也显示：采用方案1，齿轮轴零件仍会出现齿端填充不完全等缺陷；而采用方案2，齿端填充完全，未出现表面缺陷。最终得出方案2为较优工艺。

Two cold extrusion process schemes of automotive gear shaft part were presented which were the scheme 1 without back pressure device and scheme 2 with back pressure device, and the cold extrusion mold with back pressure device was designed. Then, the finite element models of two process schemes were established, and their forming processes were simulated by software Deform-3D respectively. The simulation results show that when scheme 2 is applied, the maximum values of equivalent stress, equivalent strain, damage and forming load are lower than those of scheme 1, and the forming quality is better. Meanwhile material is saved by 22% for scheme 2 compared with that of scheme 1, and the forming load is only 86% of that of scheme 1. Furthermore, the forming processes of scheme 1 and scheme 2 were verified by experiments respectively. The experimental results show that the gear shaft parts produced by scheme 1 still has the defect of insufficient filling teeth end. However, the teeth is completely filled, and no forming defect is found in gear shafts formed by scheme 2. Finally, scheme 2 is proved to be the better forming process scheme.

基金项目：

上海工程技术大学研究生科研创新资助项目(16KY0511)；上海高校青年教师培养资助计划项目(ZZGCD15035)；上海工程技术大学科研启动基金项目(校启2015-06)；上海工程技术大学产学研合作重大项目((17)CL-003)

作者简介：陈莹莹(1991-),女,硕士研究生 E-mail：18800233159@163.com 通讯作者：张莹(1980-)，女，博士，讲师 E-mail：jerrinzhang@163.com

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