从动螺旋锥齿轮双锥辊辗压成形型腔数值设计方法研究

摘要

The twin cone roll forging driven spiral bevel gear is a new technology of plastic forming spiral bevel gears. In the process of twin cone roll forging, the cavity will produce elastic deformation due to extrusion and the gear forgings will produce elastic recovery after being released from the mould. These two kinds of behaviors can affect the tooth profile accuracy of spiral bevel gear forgings. In order to improve the tooth profile accuracy, the process of the twin cone roll forging driven spiral bevel gear was simulated and analyzed based on the finite element analysis software DEFORM-3D. The elastic deformation behavior of the spiral bevel gear forging and the cavity were simulated and analyzed by using two-step method and point-tracking method; the elastic deformation law of the cavity and the elastic recovery law of the spiral bevel gear forging were obtained;the cavity was modified by the method of reverse stack correction;and the correct cavity was finally obtained.%从动螺旋锥齿轮双锥辊辗压成形是一种塑性成形螺旋锥齿轮的新工艺。辗压成形过程中，型腔会因挤压而产生弹性变形，同时，齿轮锻件脱模后会产生弹性回复，这两种行为都会影响螺旋锥齿轮锻件的齿形精度。为了提高齿形精度，在有限元分析软件DEFORM-3D 中对螺旋锥齿轮双锥辊辗压的成形过程进行数值模拟。采用两步法和点追踪相结合的方法，对螺旋锥齿轮锻件和型腔的弹性变形行为进行模拟分析，得到了成形的螺旋锥齿轮锻件的弹性回复规律和型腔的弹性变形规律，并采用反向叠加修正的方法对型腔进行修正，最终得到正确的型腔。