主动螺旋伞齿轮闭塞挤压的成形分析

分析了主动螺旋伞齿轮闭塞挤压的金属流动路线,设计了预制坯的形状。成形试验获得了金属充填齿形腔的流动模式,提出采用专用双动压力机或在通用压力机上采用特殊模具实现坯料双向挤压的成形方法。网格试验显示,塑性加工的螺旋伞齿轮金属纤维连续而致密,揭示了塑性加工齿轮强度高和使用寿命长的原因。刚塑性有限元模拟结果进一步揭示了螺旋伞齿轮塑性成形机理。有限元计算结果与试验结果的比较,证明采用有限元法研究螺旋伞齿轮闭塞挤压工艺是可行的。

Forming Analysis of Closed Die Extrusion for Spiral Bevel Driving Gear of Automotive Final Drive

In this paper, the metal flow route during closed die extrusion for spiral bevel driving gear of automotive final drive is analyzed and the profile of preformed blank has been designed. The metal flowing pattern of the tooth filling process at different stages during closed die extrusion is found through lead deformation test and double-acting extrusion method on a doubled-acting press or on a special die structure with a general press is proposed. Network test shows that the flow line distribution are continuous and dense, so it is considered to be the reason that forged gears have higher strength and longer life. Forged part and forming procedure and stroke-load curve obtained from rigid plastic FE simulation further discloses the deformation mechanics of closed die extrusion for spiral bevel driving gear. By comparison with experimental results, it would be proved that FE simulation is available and will provide guideline for deformation process of complex forging parts.