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探索一种集成了分流成形与推过整形优点的一步法斜齿圆柱齿轮精密成形新工艺,以模数为4 mm、齿数为12、螺旋角为14°、齿宽为29 mm的斜齿圆柱齿轮为研究对象,设计了成形模具,采用Deform-3D软件对成形过程进行模拟研究。首先进行了新工艺的成形力分析,之后,采用控制变量法探索了齿宽方向扩腔范围b、扩腔斜角α和齿高方向扩腔范围h这3个扩腔空间结构参数对齿轮下角隅充满效果及成形力的影响。分析结果表明,新工艺能明显降低成形力。即金属分流量的多少决定着成形效果,金属分流量由b、α和h三个参数组合决定,三者影响规律类似。即当其他条件一定时,若b(或α亦或h)过小,则成形力很大,分流量不足,导致下角隅填充不饱满;反之,虽然成形力较小,能得到完整齿形,但分流量过多,容易产生废料;当b、α和h取合理组合值:b为16 mm,α为10°和h为3 mm时,成形力适中且分流量合理,可以得到无废料的完整齿形。
To explore a new precision forming technology of one-step helical cylindrical gear with the merits of shunt-forming and pushing-shaping, the helical cylindrical with a modulus of 4 mm, a number of teeth of 12, a helix angle of 14 ° and a tooth width of 29 mm Gear as the research object, the design of the forming mold, the use of Deform-3D software to simulate the forming process. First, the forming force analysis of the new process was carried out. After that, the control variable method was used to explore the spatial structure parameters of the three expansion cavity, ie, the tooth width direction expanding cavity b, the expanding bevel angle α and the tooth height direction expanding cavity h, Corner full of effects and the impact of forming force. The analysis results show that the new process can significantly reduce the forming force. That is, how much the metal flow rate determines the forming effect, and the metal flow rate is determined by the combination of b, α and h parameters, and the influence laws of the three are similar. That is, when other conditions are constant, if b (or α or h) is too small, the forming force is large and the sub-flow rate is insufficient, resulting in incomplete filling of the corner. On the contrary, although the forming force is small, However, when the bifurcation is too large and the waste material is easy to produce, when b, α and h are reasonable combinations, b is 16 mm, α is 10 ° and h is 3 mm, the forming force is moderate and the flow rate is reasonable. Complete tooth shape.