锻压技术

基于Deform-3D的齿轮坯精锻工艺分析与试验验证

英文标题：Analysis and experimental verification of gear billet precision forging process based on Deform-3D

作者：陈保山1 逯云杰2

分类号：TG316

出版年,卷(期):页码：2023,48(12):18-24

摘要：

针对齿轮坯铸造生产质量差、精度低，而机加工生产材料利用率低、效率低的问题，采用锻造工艺进行取代。设计了齿轮坯的两种锻造成形工艺，分别为开式模锻和闭式模锻，并采用刚塑性有限元法对两种工艺进行了模拟分析。结果表明：采用开式模锻，当坯料高径比为0.23~0.53时，可获得成形完整、无缺陷的齿轮坯，且当高径比为0.53时成形力更小；采用闭式模锻，当坯料高径比为0.17~0.49时，可获得成形完整、无缺陷的齿轮坯，且当高径比为0.49时成形力更小。经对比，开式模锻的成形力更小，锻模寿命更长，而闭式模锻的材料利用率更高，锻件出现开裂的风险更低，锻件质量更好。最后，通过工艺试验获得了质量良好的齿轮坯锻件，验证了模拟结果的准确性。

For the problems of poor quality and low precision of gear billet casting production and low material utilization rate and low efficiency of machining production, the forging process was proposed to replace them. Then, two forging processes for gear billet were designed, namely open die forging and closed die forging, and they were simulated by rigid plastic finite element method, respectively. The results show that for open die forging, when the height-to-diameter ratio of billet is between 0.23 and 0.53, a complete and defect-free gear billet can be obtained, and when the height-to-diameter ratio is 0.53, the forming force is smaller. For closed die forging, when the height-to-diameter ratio of the billet is between 0.17 and 0.49, a complete and defect-free gear billet can be obtained, and when the height-to-diameter ratio is 0.49, the forming force is smaller. By comparison, the open die forging has lower forming force and longer life of forging die, while the closed die forging has higher material utilization rate, lower risk of cracking for forgings, and better quality of forgings. Finally, the good-quality gear billet forgings are obtained by process experiments, which verifies the accuracy of the simulation results.

基金项目：

作者简介：陈保山（1983-），男，硕士，讲师 E-mail：baoshan198302@163.com

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