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1、摘要齒輪是各類機(jī)械中應(yīng)用極為廣泛的重要傳動(dòng)零件,采用以凈形或近凈形為目標(biāo)的精密鍛造成形工藝生產(chǎn)齒輪件,適應(yīng)高效、精密、綠色清潔的2l世紀(jì)先進(jìn)制造技術(shù)的發(fā)展趨勢(shì),成為未來齒輪加工變革的主要方法之一。針對(duì)直齒內(nèi)齒輪精密鍛造成形工藝設(shè)計(jì)的實(shí)際要求,在總結(jié)直齒內(nèi)齒輪實(shí)際加工經(jīng)驗(yàn)的基礎(chǔ)上,提出直齒內(nèi)齒輪鐓擠和縮擠相結(jié)合的兩段成形工藝;以Pro/Engineer軟件為設(shè)計(jì)平臺(tái),對(duì)直齒內(nèi)齒輪成形模具進(jìn)行工藝設(shè)計(jì)和結(jié)構(gòu)優(yōu)化;另外通過MSC.SuperForm軟件對(duì)直齒內(nèi)齒輪精鍛成形過程進(jìn)行模擬優(yōu)化;在此基礎(chǔ)上設(shè)計(jì)實(shí)驗(yàn)?zāi)>?,并?duì)直齒內(nèi)齒輪精密鍛造成形工藝進(jìn)行實(shí)驗(yàn)分析。主要內(nèi)容如下:首先從齒
2、輪精密鍛造加工工藝入手,以分流減壓原理為理論依據(jù),提出采用縮擠和鐓擠相結(jié)合的兩段成形工藝加工直齒內(nèi)齒輪。其次利用商用有限元軟件MSC.SuperForm對(duì)直齒內(nèi)齒輪精鍛成形過程進(jìn)行數(shù)值模擬分析。分析了不同凹模型腔入模角、不同摩擦條件、不同坯料尺寸對(duì)齒形填充狀況的影響;分析了冷精鍛成形和溫精鍛成形條件下,直齒內(nèi)齒輪零件齒形的填充狀況以及成形過程中各力能參數(shù)的分布情況和變化趨勢(shì);總結(jié)了直齒內(nèi)齒輪精密鍛造成形過程中材料的流動(dòng)規(guī)律;在此基礎(chǔ)上,以Pro/Engineer軟件為設(shè)計(jì)平臺(tái),對(duì)實(shí)現(xiàn)該工藝的浮動(dòng)芯軸式模具進(jìn)行尺寸設(shè)計(jì)和修正,為直齒內(nèi)齒輪兩段成形工藝物理模擬實(shí)驗(yàn)設(shè)計(jì)實(shí)驗(yàn)?zāi)>?/p>
3、。最后對(duì)直齒內(nèi)齒輪的兩段成形過程進(jìn)行物理模擬實(shí)驗(yàn),分別用鉛和鋁兩種實(shí)驗(yàn)材料對(duì)直齒內(nèi)齒輪零件的精鍛成形過程進(jìn)行實(shí)驗(yàn)分析,并通過數(shù)據(jù)采集系統(tǒng)記錄零件成形過程中的力一行程曲線。從而驗(yàn)證了數(shù)值模擬過程中材料流動(dòng)規(guī)律,實(shí)驗(yàn)結(jié)果和數(shù)值模擬結(jié)果均驗(yàn)證了該工藝的可行性。關(guān)鍵詞精密鍛造成形工藝;數(shù)值模擬;物理模擬;兩段成形;直齒內(nèi)齒輪燕山大學(xué)工學(xué)碩士學(xué)位論文AbstractAsamostessentialdrivingpart,geariswidelyusedinallkindsofmachinesinmanyimportantindustrialfields.nleideaofpreci
4、sionforgingtechnologyaimingatNetformingorNearNetformingusedformanufacturinggearscflnadapttothetrendoftheadvancedmanufacturetechniquewiththeadvantagesofhighefficiency,precisionandenergy-saving.Inthenearfuturetheprecisionforgingtechnologywillbethemostimportantmethodforgearmanufactory.Tbedis
5、sertationputforwardanewstraightinnergearprocessingtechnologythatisthetwo—stageprocessingmethodincludingshrinkingandupsettingforming.ThedissertationputupnotonlythestructureoptimizationforthediebasedonthesoftwareofPro/Engineer,butalsothesimulationoptimizationfortheprocessingtechnologybasedo
6、nthesoftwareofMSC.SuperForm.ThenthroughthesimulationexperimentthefeasibilityoftheprocessingtechnologyWasverified.Theprimarycoverageofthedissertationasfollows:Atfirst,thedissertationputforwardthetwo—stageformingmethodforstraightinnergearincludingthetwo-stageext/Rldin噼ofshrinkingandupsettin
7、gforming.Then,thedissertationmadethenumericalsimulationfortheformingprocessingofthestraightinnergear.Somedi&rentfactorswereanalyzedincludingtheinfluenceofdifferentdiesize.different丘ictionconditionanddifferentprocessingtemperature.Throughtheanalysisofthetwo—stageproc