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1、直齒輪冷精鍛成形數(shù)值模擬分析與實(shí)驗(yàn)研究摘要本文將無限多預(yù)成形連續(xù)成形的設(shè)計(jì)思想和分流原理結(jié)合起來，初步確定了直齒輪冷擠壓成形工藝方案。該方案通過連續(xù)漸變的齒廓曲面迫使金屬向齒頂方向逐步流動(dòng)，減小了金屬充填齒腔的阻力，從而可以在改善齒輪充填性的同時(shí)降低成形力。利用三維造型軟件建立凹模型腔曲面，并通過模擬軟件仿真齒輪擠壓過程中的金屬流動(dòng)過程。模擬結(jié)果表明，齒腔充填飽滿且無塌角缺陷。采用方案比較法，基于模具形狀對(duì)傳統(tǒng)的直齒輪閉式鍛造成形方案進(jìn)行改進(jìn)。在多方案比較時(shí)，采用二維模擬的方法，節(jié)省了計(jì)算時(shí)間，降低了計(jì)算成本。簡單地探討了成形過程中的金屬流動(dòng)規(guī)律，認(rèn)為徑向流動(dòng)速度分布可以作為設(shè)計(jì)方案的評(píng)
2、價(jià)標(biāo)準(zhǔn)。最終得到一種合理可行的改進(jìn)方案，即將凸模端面設(shè)計(jì)成“w”形，凹模型腔底面設(shè)計(jì)成“一”形，對(duì)齒輪成形有利。通過對(duì)三維數(shù)值模擬實(shí)施過程中幾何建模、接觸、網(wǎng)格自適應(yīng)和重劃分等關(guān)鍵技術(shù)問題的處理，Jiron完成傳統(tǒng)方案和改進(jìn)方案的模擬。由兩方案的數(shù)值模擬結(jié)果對(duì)比可知：改進(jìn)方案的應(yīng)力應(yīng)變及徑向流動(dòng)速度分布均勻：改進(jìn)方案的成形效果好，克服了齒輪上下角隅充填不滿的缺陷，同時(shí)降低了成形力及能耗。實(shí)驗(yàn)結(jié)果和模擬結(jié)果具有良好的一致性，從而進(jìn)一步證明本文所提出的改進(jìn)方案是合理可行的。關(guān)鍵詞：直齒輪擠壓閉式鍛造數(shù)值模擬Numericalsimulationandexperimentalresearcho
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5、effectisgood．Scenariocomparisonmethodwasadoptedtoimprovetheconventionalschemeofclosed—dieforgingofspurgearbasedonmoldshape．Two·dimensionalsimulationsareperformedincomparisonofschemes，whichsavesalotoftimeanddecreasesthecomputingcost．Theruleofmetalmaterialflowintheformingprocessisdiscussedinbrief,a
6、ndaconclusionthatthedistributionsofmaterialradical．flow-velocityCallbeusedtoevaluatethedesignschemeisdrawn．Finally,afeasibleimprovedschemewithpunchendsurfaceifi”w’’shapeanddiebottomsurfacein”—’、”shapeisputforward．Tocontinuethenumericalsimulationsoftheconventionalandimprovedschemes，somekeytechnolo
7、gies，includinggeometricmodel，contact，meshadaptingandremeshing，aresolved．Bycomparisonofthesimulationsresultsofthetwoschemes，themainconclusionsobtainedareasfollows：thedistributionsofstress，strainandradical—flow—velocitya
