锻压技术

基于Deform3D的带齿轴套锻造工艺仿真与实践

英文标题：Simulation and practice on forging process for toothed shaft sleeve based on Deform-3D

作者：李月超李婷

分类号：TG316.3；TP391.9

出版年,卷(期):页码：2022,47(6):93-98

摘要：

某带齿轴套需经过缩径、镦粗、反挤压、冲孔等多级锻造实现成形，其工艺复杂、效率低、成本高，急需改进。提出了一种闭式锻造新工艺，采用组合式冲头结构实现了一次锻造成形。并利用有限元技术对改进后的工艺进行了全面分析，包括带齿轴套的成形经过、应力应变分析、载荷曲线变化、轴套锻后温度分布等。根据模拟结果可知，改进后的工艺简单可靠，得到的带齿轴套充填完整，不存在表面缺陷，内部流线连续均匀，质量较好。在同等条件下利用液压机进行了锻造试验，获得的产品与模拟效果一致，经质检，产品的齿形清晰完整，各处尺寸均能达到要求，表明改进后的工艺能起到提高生产效率和降低成本的作用，同时证实了有限元技术在工艺研究方面的指导作用。

A toothed shaft sleeve needs to be formed by multi-stage forging such as reducing diameter, upsetting, back extrusion and punching, and the process was complex with low efficiency and high cost, which needs to be improved urgently. Therefore, a new closed forging process was proposed by using combined punch structure to realize one-time forging, and the improved process was comprehensively analyzed by finite element technology including the forming process of toothed shaft sleeve, stress-strain analysis, load curve change and temperature distribution after shaft sleeve forging. According to the simulation results, the improved process is simple and reliable, the toothed shaft sleeve is completely filled without defects on surface, the internal streamline is continuous and uniform, and the quality is good. Under the same conditions, the forging test was carried out by hydraulic press, and the product obtained was consistent with the simulation effect. Through quality inspection, the tooth shape of product is clear and complete, and all the dimensions meet the requirements. The results show that the improved process improves the production efficiency and reduces the cost, and the guiding role of finite element technology in process research is confirmed.

基金项目：

李月超（1984-），男，硕士，讲师 E-mail：382645303@qq.com 通信作者：李婷（1989-），女，硕士，讲师 E-mail：304229759@qq.com

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