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针对倒档棘轮外齿上下不对称的特点,制定了倒档棘轮外齿两种冷精锻成形工艺方案。采用Deform-3D有限元软件对其精锻成形过程进行数值模拟分析,比较了两种成形工艺方案中的金属流速及充填效果。分析结果表明,采用成形+切削的工艺方案成形倒档棘轮外齿时,金属流动均匀,充填效果理想。采用成形+切削工艺进行生产试制表明,倒档棘轮外齿成形件的凸台底部角隅处充填饱满、齿轮齿面完整,外齿成形精度及抗疲劳强度得到提高。
In view of the characteristics of reverse ratchet external teeth asymmetric up and down, developed a reverse gear ratchet two cold precision forging forming process. Deform-3D finite element software was used to carry out numerical simulation analysis of its precision forging process. The metal flow rate and filling effect in two forming process schemes were compared. The analysis results show that the metal flow is uniform and the filling effect is ideal when the reverse gear ratchet gear is formed by the forming and cutting process scheme. The production trial of the forming + cutting process shows that the bottom of the boss of the reverse gear ratchet gear is fully filled, the gear tooth surface is complete and the forming accuracy and fatigue resistance of the external gear are improved.