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针对载重汽车用直齿轮采用“冷挤压后再冷精整”工艺方案成形后精度不能稳定到8级、后续加工余量大的问题,提出“冷挤压-冷精整”复合成形工艺方案,建立直齿轮复合成形弹塑性有限元模型。由数值模拟结果可知,精整量对直齿轮成形精度和成形质量影响较大,当精整量为0.15 mm时,经复合成形的齿轮齿顶塌陷量小、成形精度高。针对模拟结果进行工艺实验,并对成形后齿轮进行检测,结果显示:齿轮齿形精度为6级,齿向精度稳定至8级,齿轮上、下端齿顶均达到后续机械加工要求,上下端面加工余量减小,材料利用率得到有效提高。
For the use of spur gears for truck, the precision of the process scheme of “Cold Extrusion and Cold Finishing” after forming can not be stabilized to level 8, and the follow-up machining allowance is large. It is proposed that “cold extrusion-cold finishing” Composite forming process scheme, the establishment of spur gear composite forming elasto-plastic finite element model. The numerical simulation results show that the amount of finishing has a great influence on the forming accuracy and the forming quality of the spur gear. When the finishing amount is 0.15 mm, the gear tip collapse amount is small and the forming accuracy is high. According to the result of the simulation, the experiment of gear was carried out and the gear after forming was tested. The result shows that the gear tooth profile accuracy is 6, the tooth orientation accuracy is stable to 8, the top and bottom tooth tips of the gear reach the requirements of subsequent machining, Reduce the margin, material utilization has been effectively improved.