直齿圆柱齿轮冷挤压可控运动凹模成形工艺

为降低直齿圆柱齿轮冷挤压成形载荷和改善齿形角隅部分充填性,在分析直齿圆柱齿轮成形过程中金属流动特性基础上,提出了采用可控运动凹模的成形工艺。利用Deform-3D软件对此成形工艺过程中的金属流动规律、成形载荷、成形缺陷进行了数值模拟分析,并对该工艺进行了优化。分析结果表明,当凹模速度为冲头速度的1/2时,成形过程中齿形充填均匀、齿形角隅部分充填饱满,成形载荷最小,较传统单向挤压成形载荷降低了约20%。对优化后的成形工艺进行了成形试验研究,试验成形齿轮齿形饱满,无塌角缺陷,试验结果与模拟结果基本吻合。

Forming technology of controlled movable die of spur gear in cold extrusion

In order to reduce the forming load of spur gear in cold extrusion and improve the metal filling in tooth corner, a controlled movable die forming process was developed by analyzing metal flow characteristics of spur gears in forming process. The regulation of metal flow, forming load and forming defects in the forming process were numerically simulated by Deform-3D, and the forming process was optimized. The analysis results show that when the speed of die is half of punch speed, the tooth shape is filled evenly in the forming process with full filling at its corner portion, and the forming load is the smallest. Furthermore, the forming load is reduced about 20%compared with that of traditional one-way extrusion forming. The optimal process was studied by experiment, and the experimental gear tooth forms fully without angle collapsings. The simulation result is in agreement with experimental results.