圆柱齿轮滚轧成形工艺的虚拟设计与数值分析
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摘要
伴随着齿轮的广泛应用,齿轮制造技术也不断的改善发展。锻造、摆辗、挤压、楔横轧、滚轧等齿轮塑性成形工艺因为其高效率、高强度、高精度的加工特点而成为节能环保的一个有效方法,同时也得到了许多的研究和关注。
齿轮滚轧成形工艺作为一种新工艺,以齿轮啮合特点为基础,利用机床的进给特点,在模具的作用下,使轧坯表层金属逐渐发生连续的塑性变形,填充模具与轧坯之间的空隙,直至形成完整齿形。在齿轮滚轧的过程中轧坯金属流动、轧轮轧制运动的平稳性、成形力变化、物理场分布等都会随着辊轧过程的变化发生相应的改变。同时,圆柱斜齿轮滚轧成形工艺中,轴向力对辊轧工艺的影响还并不确定。由于齿轮滚轧成形缺少相关的数据与经验理论,在辊轧过程中,轧轮与坯料的尺寸与运动参数都需要实验逐步确定。因此本文利用DEFORM-3D软件对圆柱齿轮滚轧成形过程进行模拟分析,对圆柱齿轮辊轧工艺的可行性进行验证,对齿轮滚轧成形工艺进行研究。
圆柱齿轮轧制成形工艺的研究内容与结果：
(1)建立辊轧模型：确定坯料尺寸参数、轧辊工艺参数。创建并确定坯料与轧轮配合模型。
(2)齿轮轧制机理：基于DEFORM-3D有限元分析软件,对齿轮轧制成形过程进行模拟分析。获取齿轮轧制成形过程中坯料变形与机械载荷的关系；获取齿轮轧制工艺过程中,齿坯金属流动情况；检测轧制工艺中,齿坯应力场与温度场分布情况。
(3)齿轮轧制成形工艺与优化：模拟圆柱齿轮轧制成形工艺过程,并对轧制工艺参数进行优化分析：根据齿轮成形状况对齿坯尺寸进行优化。
(4)齿轮轧制成形缺陷预测与分析：对圆柱齿轮轧制成形工艺过程的缺陷进行预测；对轧制成形工艺实际缺陷进行分析与改进。
Gear plastic forming process including forging, rotary forging, extrusion, cross wedge rolling and cylindrical rolling become an more energy conversation way to produce gears as the extensive use of gears and improvement of gear manufacturing technologies. The gear forming processes have been concerned and studied in these years.
Gear cylindrical rolling is a new process, it based on the character of gear engagement, drive the rollers by machine to make the surface metal of workpiece occur plastic deformation to fill the gap between roller and workpiece until complete profile formed. In the forming process, metal flowing, smooth movement of rollers, forming force, physical distribution will change with the roller and time. However, standard theoretical system of gears forming has not been established, the impact of axial force to the process is not sure, and the size and movement parameters of roller and workpiece should to be assured by experiment because of lack gear forming theory and data. So cylindrical gear rolling process was simulated and analyzed in this paper, the feasibility of gear rolling process was verified.
Research and results of cylindrical gear rolling process:
(1) The establishment of rolling model:calculated dimensions of workpiece and roller, chose movement parameters of roller, established rolling model of gear rolling.
(2) Gear rolling mechanism:simulated and analyzed gearing rolling process by DEFORM-3D finite element analysis software (DEFORM-3D). The mechanical load, workpiece deformation and metal strain had been got to analyze metal flow of workpiece. Stress field and temperature field were observed. And the fold could be seen in the DEFORM-3D.
(3) Gear rolling process and optimization:the cylindrical gear rolling process had been simulated and the process parameters had been analyzed, the size of workpiece had been optimized based on deformation conditions.
(4) Forecast and analysis of gear rolling defects:defects of cylindrical gear rolling process had been predicted and analyzed, optimization method had been proposed.
齿轮滚轧成形工艺作为一种新工艺,以齿轮啮合特点为基础,利用机床的进给特点,在模具的作用下,使轧坯表层金属逐渐发生连续的塑性变形,填充模具与轧坯之间的空隙,直至形成完整齿形。在齿轮滚轧的过程中轧坯金属流动、轧轮轧制运动的平稳性、成形力变化、物理场分布等都会随着辊轧过程的变化发生相应的改变。同时,圆柱斜齿轮滚轧成形工艺中,轴向力对辊轧工艺的影响还并不确定。由于齿轮滚轧成形缺少相关的数据与经验理论,在辊轧过程中,轧轮与坯料的尺寸与运动参数都需要实验逐步确定。因此本文利用DEFORM-3D软件对圆柱齿轮滚轧成形过程进行模拟分析,对圆柱齿轮辊轧工艺的可行性进行验证,对齿轮滚轧成形工艺进行研究。
圆柱齿轮轧制成形工艺的研究内容与结果：
(1)建立辊轧模型：确定坯料尺寸参数、轧辊工艺参数。创建并确定坯料与轧轮配合模型。
(2)齿轮轧制机理：基于DEFORM-3D有限元分析软件,对齿轮轧制成形过程进行模拟分析。获取齿轮轧制成形过程中坯料变形与机械载荷的关系；获取齿轮轧制工艺过程中,齿坯金属流动情况；检测轧制工艺中,齿坯应力场与温度场分布情况。
(3)齿轮轧制成形工艺与优化：模拟圆柱齿轮轧制成形工艺过程,并对轧制工艺参数进行优化分析：根据齿轮成形状况对齿坯尺寸进行优化。
(4)齿轮轧制成形缺陷预测与分析：对圆柱齿轮轧制成形工艺过程的缺陷进行预测；对轧制成形工艺实际缺陷进行分析与改进。
Gear plastic forming process including forging, rotary forging, extrusion, cross wedge rolling and cylindrical rolling become an more energy conversation way to produce gears as the extensive use of gears and improvement of gear manufacturing technologies. The gear forming processes have been concerned and studied in these years.
Gear cylindrical rolling is a new process, it based on the character of gear engagement, drive the rollers by machine to make the surface metal of workpiece occur plastic deformation to fill the gap between roller and workpiece until complete profile formed. In the forming process, metal flowing, smooth movement of rollers, forming force, physical distribution will change with the roller and time. However, standard theoretical system of gears forming has not been established, the impact of axial force to the process is not sure, and the size and movement parameters of roller and workpiece should to be assured by experiment because of lack gear forming theory and data. So cylindrical gear rolling process was simulated and analyzed in this paper, the feasibility of gear rolling process was verified.
Research and results of cylindrical gear rolling process:
(1) The establishment of rolling model:calculated dimensions of workpiece and roller, chose movement parameters of roller, established rolling model of gear rolling.
(2) Gear rolling mechanism:simulated and analyzed gearing rolling process by DEFORM-3D finite element analysis software (DEFORM-3D). The mechanical load, workpiece deformation and metal strain had been got to analyze metal flow of workpiece. Stress field and temperature field were observed. And the fold could be seen in the DEFORM-3D.
(3) Gear rolling process and optimization:the cylindrical gear rolling process had been simulated and the process parameters had been analyzed, the size of workpiece had been optimized based on deformation conditions.
(4) Forecast and analysis of gear rolling defects:defects of cylindrical gear rolling process had been predicted and analyzed, optimization method had been proposed.
引文
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[2]上海汽车齿轮厂,上海市机械制造工艺研究所.热轧齿轮原理及工艺[J].汽车技术,1974,(3)：55～59
[3]刘渭贤.热轧齿轮小结[J].南京：南京航空航天学院学报,1959,(3)：69～78
[4]R.Neugebauer,M.Putz,U.Hellfritzsch. Improved process design and quality for gear manufacturing with flat and round rolling[J].Manufacturing Technology.2007, 56(1):307-312
[5]Dr.Ing.e.h.Heinz Tschaetsch, Kaiserplatzra. Metal forming practice[M].Germany,2005, 56-76
[6]W.Voelkner. Present and future developments of metal forming:selected examples[J]. Journal of Materials Processing Technology,2000,106 (1～3):236-242
[7]Z.Pater. Theoretical and experimental analysis of cross wedge rolling process[J]. International Journal of Machine Tools & Manufacture,2000,40 (1):49-63
[8]盛伯浩.对热轧齿轮问题的商榷[J].机床与工具,1959,(6)：1～5
[9][苏]P.H.Cabnhlieb大模数齿轮的轧制[J].模具技术,1989,(6)：87～96
[10][苏]A.I.Kyamnh,M.B.Bacmjbqnkom齿轮轧制法[J].机械制造,1956,(8)：38～39
[11]许协和,李玉京,颜世公.伞齿轮坯的斜轧及其孔型设计[J].锻压技术,1984,(1)：11～16
[12]王华君,夏巨谌,张猛.螺旋伞齿轮复动闭式模锻模具[J].锻压装备与制造技术,2005,(2)：93～94
[13]王华君,夏巨谌,程培元,等.从动螺旋伞齿轮精密锻造数值仿真[J].华中科技大学学报,2005,33(9)：94～96
[14]张猛,黄尚宇,赵玉民,等.汽车螺旋伞齿轮封闭模锻造成形的变形特性[J].中国有色金属学报,1999,9(3)：567～572
[15]张猛,赵玉民,黄尚宇,等.螺旋伞齿轮塑性成形实验研究[J].锻压技术,1999,(1)：3～5
[16]Y anling Ma,Yi Qin,Raj Balendra. Forming of hollow gear-shafts with pressure-assisted injection forging(PAIF)[J]. Materials Processing Technology 2005,167(2～3):294-301
[17]张炳君,孙岳康.热轧柴油机正时齿轮新工艺[J].机械制造,1982,(4)：20～23
[18]汗建余.圆柱直齿轮滚轧制坯-镦挤、胀挤复合精成形的虚拟设计[D].吉林：吉林大学,2004
[19]任志刚.硬齿面齿轮热滚挤技术工艺与装备研究[D].沈阳：沈阳工业大学,2007
[20]李亚敏.螺旋锥齿轮摆辗成形关键技术研究[D].武汉：武汉理工大学.2009
[21]史双喜.对称双锥辊轴向轧制螺旋锥齿轮工艺研究[D].武汉：武汉理工大学,2008
[22]应富强.渐开线齿轮轴楔横轧成形机理、模拟分析及实验研究[D].上海：上海大学,2007
[23]朱振麟.国内热轧齿轮情况综述[J].锻压机械,1979,(4)：61-68
[24][德]D.Schmoeckl齿轮的轧锻成形[J].国外汽车,1982,(2)：63～67
[25]应富强,潘孝勇,李敏.基于有限变形理论的齿轮楔横轧制坯热力耦合模拟[J].中国工程科学,2007,9(7)：47-52
[26]周启铭,潘正元.小模数齿轮冷轧的初步效果[J].机械制造,1959,(11)：15～25
[27]赣州冶金汽车修理厂.螺旋伞齿轮的热轧试验[J].汽车技术,1973,(3)：77～78
[28][美]C.M.黑辛.热轧齿轮[J].机床与模具.1956,(17)：43～44
[29]新沪钢铁厂.用煤炉加热土法轧制齿轮成功[J].机床与工具,1958,(11)：28～31
[30]严光达.两种冷轧齿轮新工艺及其设备[J].锻压机械,1982,(5)：61～64
[31][苏]J.C.Crockett小齿轮冷轧[J].仪器制造,1975,(2)：33～37
[32]于荣贵.渐开线螺旋花键冷滚轧模[J].机械工人.999.(9)：41～42
[33]吕新民.用热轧空心棒材制造汽车齿轮[J].机械制造,1985,(5)：29
[34]何永秀摘译.淬火齿轮的轧制精加工[J].装备环境工程,1992,(6)：269
[35]北京汽车修理公司.螺旋伞齿轮研磨器[J].汽车技术,1971,(3):69～75
[36]郭自新.伞齿轮的制造工艺[J].机床与工具,1954(19)：22～25
[37]凌文锋.螺旋伞齿轮新加工方法及关键技术的研究[D].北京：北京交通大学,2008
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