斜齿伞齿轮精锻成形工艺研究
Research on the Precision Forging Process of Skew Bevel Gear
徐戊矫，邹明平，李珊珊，杨沛东
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作者单位：重庆大学材料科学与工程学院
中文关键字：斜齿伞齿轮；精锻成型；数值模拟；DEFORM
英文关键字：skew bevel gear; precision forging; numerical simulation; DEFORM
中文摘要：斜齿伞齿轮是机械传动中的重要零件，区别于传统的机械加工成形，精密锻造成型从产品质量、使用可靠性和经济效益方面具有显著优势。结合斜齿伞齿轮精锻成型的材料流动特点，确定了精锻工艺的坯料为圆管坯，并选择了外径定位的成形方式。建立了斜齿伞齿轮精锻成型工程的数值模拟仿真模型，研究了坯料高度值、坯料上端外径处圆角半径值及坯料偏置对成型过程的影响。研究发现，环坯的高度对成型过程中的最大载荷和应变均匀性有较大影响，坯料顶端外径圆角可消除充型时大端齿槽处因材料下翻产生的折叠，少量的坯料不对中对成形过程无影响，从而优化坯料高度为71mm，顶端外径处圆角为R10。本研究为从动斜齿伞齿轮的批量热精锻生产提供了理论指导。
英文摘要：The skew bevel gear is a very important component in mechanical transmission. Compared to the traditional machining processing method, precision forging has large advantages in product quality, service reliability and economic efficiency. Based on the material flow characteristics in the precision forging of skew bevel gear, the tube billet is chosen for the precision forging billet and location forms by external diameter is chosen. The influence of billet height, fillet radius and billet misalign to the forming process is analysed. The simulation shows that billet height can greatly influence the forming load and the consistency of equivalent strain, that the fillet radius on the top of billet can eliminate the fold caused by the material flow when gear groove on the bigger side is shaped, that the billet misalign has no effect on the forming process. The optimized billet height is 71mm and the optimized fillet radius is 10mm. The research is helpful for the hot precision forging of skew bevel gear volume produce .