齿轮闭式锻造新工艺方案的数值模拟研究

齿形充填不满和成形力过高是齿轮闭式锻造典型方案的缺陷。模具几何形状是影响金属塑性流动的主要因素之一,通过改变模具的几何形状可以改变金属的塑性流动。文章通过有限单元法,对3种设计方案进行了二维模拟计算,从数值模拟结果中获得了各方案的应变场和速度场的分布情况,并进行比较分析,得出一种合理可行方案,该方案的坯料沿径向流动速度分布较为均匀;最后,通过三维有限元模拟技术进一步对可行方案进行验证,发现齿轮充填饱满,成形效果较好。

Numerical simulation research on a new technological scheme for closed-die forging spur gear

Unsuccessful corner filling and excessive deformation force are the main limitations of classical cold closed-die forging of straight spur gear.The mold shape is one major factor which affects metal deformation rules,but metal plastic deformation process can be controlled through the change of the mold shape.The finite element method is used herein to simulate the cold forging process of the spur gear,and three design schemes with different mold and die shapes are researched.Also the strain distributions and velocity distributions are investigated.A feasible scheme is attained by analyzing two-dimensional numerical simulation results of these schemes.Finally,the feasible scheme is further validated by three-dimensional numerical simulation,and the simulation results show that the corner filling is improved and the whole forming effect is good.