锻压技术

齿轮温锻模具磨损失效分析

英文标题：Analysis on wear failure of warm forging die for gear

作者：张继方晋会杰徐颖若

分类号：TG376.2

出版年,卷(期):页码：2022,47(5):38-44

摘要：

为了延长齿轮温锻凹模的使用寿命，借助DEFORM软件和Archard模型对齿轮闭式温锻成形过程进行模拟分析，预测凹模磨损最严重区域，并利用响应曲面法建立齿轮温锻凹模磨损量编码因子方程，以凹模预热温度、凹模硬度、冲孔连皮厚度和凹模齿顶过渡圆角半径作为目标参数对凹模磨损最严重区域进行参数化分析。预测结果表明：齿轮齿形填充饱满，轮齿不存在塌角现象，优化后磨损最严重区域的磨损量为1.42×10-5 mm，与回归模型预测值比率相差5.63%，误差较小；对应的最优参数组合为：凹模预热温度为150 ℃、凹模硬度为55 HRC、冲孔连皮厚度为2.7 mm和凹模齿顶过渡圆角半径为0.4 mm，预测齿轮温锻凹模寿命为7746件，符合生产预期的6500件。说明响应曲面法预测结果较为准确，可一定程度上降低试模成本。

In order to extend the service life of warm forging die for gear, the closed warm forging process of gears was simulated and analyzed by software DEFORM and model Archard, the most serious wear area of die was predicted, and the code factor equation for wear amount of warm forging die for gear was established by the response surface method. Then, taking die preheating temperature, die hardness, punched skin thickness and transition fillet radius of die tooth tip as target parameters, the most serious wear area of die was parametrically analyzed. The prediction results show that the gear tooth profile is fully filled, and there is no slump in the gear teeth. After optimization, the wear amount in the most serious wear area is 1.42×10-5 mm, which is 5.63% different from the predicted value of the regression model, and the error is small. The optimal parameters combination is the die preheating temperature of 150 ℃, the die hardness of 55 HRC, the punched skin thickness of 2.7 mm and the transition fillet radius of die tooth tip of 0.4 mm, and the predicted service life of warm forging die for gear is 7746 pieces, which is in line with the production expectations of 6500 pieces. Thus, the prediction results of the response surface method are more accurate and can reduce the trial cost to a certain extent.

基金项目：

2019年度河南省高等学校青年骨干教师培养计划项目(2019GGJS280)

作者简介：张继方(1991-)，男，硕士，助教，E-mail：991972669@qq.com；通信作者：徐颖若（1991-），女，硕士，助教，E-mail：289425501@qq.com

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