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基于约束分流原理,以某厂生产的减速小齿轮为例,采用数值模拟和物理试验相结合的方法,对直齿圆柱齿轮精锻成形工艺进行了深入研究。通过分析小芯棒约束分流和凸缘分流两种方案下坯料孔径的大小对直齿圆柱齿轮成形过程的影响,确定出可以改善充填性与降低工作载荷的最佳工艺方案:浮动凹模下坯料尺寸为直径38 mm、孔径16 mm、高度27.3 mm的小芯棒约束分流与固定凹模下坯料尺寸为直径38 mm、孔径18 mm、高度25.5 mm的凸缘分流。由小芯棒约束分流浮动凹模形式下的力-行程曲线可知,试验结果与有限元数值模拟结果能很好地吻合。
Based on the principle of restrained shunting, taking the deceleration pinion gear produced by a factory as an example, the precision forging process of spur gear has been deeply studied by the combination of numerical simulation and physical experiment. By analyzing the influence of the size of billet aperture on the spur gear forming process under the two schemes of constrained shunt and flange shunting, the best process scheme to improve the filling property and reduce the working load is determined: A small mandrel bar having a diameter of 38 mm, a bore diameter of 16 mm and a height of 27.3 mm constrained the bifurcation of a flange with a diameter of 38 mm, a bore diameter of 18 mm and a height of 25.5 mm under a split and fixed die. From the force-stroke curve under the mode of shunt floating small die confined by small mandrel, the experimental results are in good agreement with the numerical simulation results of finite element method.