锻压技术

基于齿顶分流的铜制齿环热锻成形工艺方案设计

英文标题：Design on hot forging process scheme for copper gear ring based on tooth top shunt

作者：夏洪均唐全波李永亮梁强

单位：重庆工商大学

分类号：TG316

出版年,卷(期):页码：2022,47(7):20-27

摘要：

以某款HMn64-8-5-1.5锰黄铜制齿环为研究对象，通过有限元模拟仿真，设计其热锻成形工艺方案并进行工艺实验验证。首先，通过等温热压缩实验获取HMn64-8-5-1.5合金在变形温度为873~1073 K、应变速率为0.01~10 s-1及变形量为60%条件下的真应力-真应变数据，以此为基础，通过非线性曲线拟合构建其Hansel-Spittel本构模型。其次，应用该本构模型建立齿环热锻成形有限元模型，模拟仿真了该齿环热锻成形过程，分析得到花键齿齿尖处充填不饱满的原因为：金属充填花键齿型腔时，在齿尖处形成了封闭的空腔，从而出现憋气现象，导致齿尖处充填不饱满。最后，针对该问题提出一种齿顶分流的解决思路，即在原模具齿顶处设计分流槽。经数值模拟与工艺实验验证，采用该方法可以有效地解决齿环热锻成形后花键齿齿尖充填不饱满的问题。

For the HMn64-8-5-1.5 manganese brass gear ring, the hot forging process scheme was designed by finite element simulation, and the process test was verified. Firstly, the true stress-true strain data of HMn64-8-5-1.5 alloy under the conditin of the deformation temperatures of 873-1073 K, the strain rates of 0.01-10 s-1 and the deformation amount of 60% was obtained by the isothermal hot compression tests, and on this basis the Hansel-Spittel constitutive model was constructed by nonlinear curve fitting. Secondly, a finite element model of the hot forging for gear ring was established by using the Hansel-Spittel constitutive model, and the hot forging process of gear ring was simulated. Furthermore, the reasons for the insufficient filling at the spline tooth tip were analyzed. When the metal filled the cavity of spline tooth, a closed cavity was formed at the tooth tip, and the phenomenon of suffocation occurred, resulting in insufficient filling at the tooth tip. Finally, in view of the above problem, a solution thought to the tooth top shunt was proposed, namely, a shunt groove at the tooth top of the original mold was designed. The results of numerical simulation and process test show that the problem of insufficient filling of spline tooth tips after hot forging of the gear ring can be effectively solved.

基金项目：

重庆市教育委员会科学技术研究项目(KJQN201900836)

作者简介：夏洪均（1972-），男，学士，高级实验师 E-mail：601169440@qq.com

参考文献：

[1]Cui H Y, Tian N, Li R C, et al. A method of parametric design of automobile synchronizer ring based on UG secondary development tools [J]. Applied Mechanics and Materials, 2015, 716-717: 635-638.

[2]Zhang M, Hua L, Song Y L, et al. Effects of parameters on fine blanking of steel synchronizer ring teeth [J]. Advanced Materials Research, 2014, 941-944: 1671-1677.

[3]马斌，梁强，李平. 参考条件对M-JC和M-ZA模型预测精度的影响[J]. 锻压技术，2021，46（5）：253-260.

Ma B, Liang Q, Li P. Influence of reference condition on prediction precise for modified Johnson-Cook and modified Zerilli-Armstrong models [J]. Forging & Stamping Technology, 2021, 46(5): 253-260.

[4]梁强，刘静. 基于灰色系统理论的同步器齿环的成形工艺研究[J]. 特种铸造及有色合金，2019，39（5）：483-486.

Liang Q, Liu J. Forming process of hot precision forging for synchronizer ring based on grey system theory [J]. Special Casting & Nonferrous Alloys, 2019, 39(5): 483-486.

[5]王梦寒，邵长伟，徐志敏，等. 同步器齿环模锻金属流动规律分析及工艺改进[J]. 热加工工艺，2010，39（13）：19-22.

Wang M H, Shao C W, Xu Z M, et al. Analysis of metal flow and technology improvement on synchronizer ring precision die-forging [J]. Hot Working Technology, 2010, 39(13): 19-22.

[6]邵长伟，周杰，王梦寒，等. 基于有限元法的精密锻造齿环齿顶折叠的研究[J]. 热加工工艺，2010，39（11）：97-99，102.

Shao C W, Zhou J, Wang M H, et al. Analysis on folding of gear top in synchronizer ring precision forging based on FEM [J]. Hot Working Technology, 2010, 39(11): 97-99，102.

[7]马斌，李平，梁强. HNi55-7-4-2合金高温本构模型构建及应用[J]. 兵器材料科学与工程，2020，43（4）：108-113.

Ma B, Li P, Liang Q. Construction and application of high-temperature constitutive model of HNi55-7-4-2 alloy [J]. Ordnance Material Science and Engineering, 2020, 43(4): 108-113.

[8]马斌，李平，梁强，等. 同步器齿环用HNi55-7-4-2合金高温本构模型构建及应用[J]. 材料热处理学报，2020，41（12）：146-155.

Ma B, Li P, Liang Q, et al. Construction and application of high-temperature constitutive model of HNi55-7-4-2 alloy for synchronizer gear ring [J]. Transactions of Materials and Heat Treatment, 2020, 41(12): 146-155.

[9]Xue S, Zhou J. A research on steel synchronizer gear ring′s precision forging [J]. Materials Science Forum, 2008, 575-578:226-230.

[10]梁强，张贤明，贾艳艳. 基于灰色关联分析的直齿轮冷挤压成形工艺参数优化[J]. 塑性工程学报，2021，28（1）：69-76.

Liang Q, Zhang X M, Jia Y Y. Parameter optimization in cold extrusion process for spur gear based on grey relational analysis [J]. Journal of Plasticity Engineering, 2021, 28(1): 69-76.

[11]危康. 基于SVM-IMPSO模型的薄壁齿环零件热锻成形工艺稳健优化设计[D]. 重庆：重庆大学，2017.

Wei K. Rubust Optimization of Hot Forging Process of Thin-walled Gear Ring Based on SVM-IMPSO Model [D]. Chongqing: Chongqing University, 2017.

[12]刘左发，冯文杰，陈莹莹. 离合器外齿毂冷挤压成形工艺参数多目标优化[J]. 塑性工程学报，2020，27（4）：13-20.

Liu Z F, Feng W J, Chen Y Y. Multi-objective optimization of cold extrusion forming process parameters for clutch outer gear hub [J]. Journal of Plasticity Engineering, 2020, 27(4): 13-20.

[13]郭乐乐，陈学文，周旭东，等. 基于原位观测的Cr5合金钢Hansel-Spittel高温本构模型修正方法及试验验证[J]. 塑性工程学报，2021，28（6）：88-95.

Guo L L, Chen X W, Zhou X D, et al. Correction method and experimental verification of Hansel-Spittel constitutive model of Cr5 alloy steel at high temperature based on in-situ observation [J]. Journal of Plasticity Engineering, 2021, 28(6): 88-95.

[14]尹小燕，骆静，朱杰. 基于Hansel-Spittel模型的齿环用HAl61- 4-3-1合金本构模型构建[J]. 重庆理工大学学报：自然科学，2021，35（1）：111-117，167.

Yin X Y, Luo J, Zhu J. Construction of high-temperature constitutive model of HAl61-4-3-1 alloy for synchronizer ring based on Hansel-Spittel mode [J]. Journal of Chongqing Institute of Technology: Natural Science, 2021, 35(1): 111-117, 167.

[15]李露，周旭东，陈学文，等. PCrNi3MoV钢Hansel-Spittel流变应力模型[J]. 河南科技大学学报:自然科学版，2020，41（6）：1-5,10,115.

Li L, Zhou X D, Chen X W, et al. Hansel-Spittel flow stress model of PCrNi3MoV steel [J]. Journal of Henan University of Science & Technology: Natural Science, 2020, 41(6): 1-5, 10, 115.

服务与反馈：

【文章下载】【加入收藏】