某齿轮坯精锻金属流动规律分析及工艺优化
Metal Flow Analysis of Precision Forging Process and Technology
曾德涛，周杰，张辉，刘太钟，陈世江
点击：2248次 下载：0次
作者单位：重庆大学材料学院
重庆秋田齿轮有限责任公司
中文关键字：齿轮坯 数值模拟 充填顺序 模具结构
英文关键字：gear blank; numerical simulation; filling order; die structure
中文摘要：分析了齿轮坯成形过程中金属的流动特点，针对齿轮坯在锻造过程中径向筋条出现的充填不饱满现象，为了改变筋条部分的充填状态，本文提出了将终锻成形筋条的金属流动方式由径向流动为主变为轴向敦挤为主的方式。应用刚塑性有限元法对齿轮坯成形过程进行了模拟，得出径向筋条充填不饱满是因为不合理的充填顺序。通过改变模具的结构，有效地改变了筋条成形时金属的流动的状态，得到了合理的充填顺序。模拟结果显示，筋条成形饱满。通过生产实践，锻件与模拟结果一致，其力学性能和尺寸精度等也符合要求。材料利用率从48%提高到67.9%。
英文摘要：The metal flow ruler in gear blank forging process was analyzed. In order to eliminate unsuccessful filling on radial direction rib during forming process, the radial extrusion was replaced by the method of upsetting and extruding in final forming to optimize metallic flow actions in this paper. The gear blank forging process was simulated by rigid-plastic finite element model. The results show that unsuccessful filling ascribes to unreasonable filling order. Reasonable metallic flow actions and filling order can be obtained by optimizing die structure. Simulation results show that new process can achieve full ribs. After production practice，formings are consistent with simulation results and its mechanical property and dimensional accuracy also accord with the requirement. The material utilization rates improved from 48%to 67.9% now.