【作者】 胡锐；

【导师】 程培元；

【作者基本信息】 武汉理工大学 ， 材料加工工程， 2006， 硕士

【摘要】 摆动辗压是一种局部加压连续塑性成形技术。直齿圆锥齿轮摆动辗压精密成形工艺是一种先进的齿轮加工技术，具有材料利用率高、生产率高、生产成本低、齿轮机械性能好和使用寿命高、成形尺寸精度高等诸多优点。在齿轮加工领域有着广泛的应用。 本文在研究直齿圆锥齿轮摆动辗压工艺的基础上，利用有限元法分析了齿形成形过程中金属的填充规律，阐述了直齿圆锥齿轮摆动辗压成形特点，讨论了引起摆动辗压凹模的失效本质原因。 根据齿轮零件及摆辗模具原型，利用三维造型软件UG对零件及模具进行造型，得到直齿圆锥齿轮摆动辗压成形的模具及零件模型，为成形工艺有限元模拟分析提供了依据。 基于刚塑性有限元理论，建立了直齿圆锥齿轮摆辗成形的有限元分析模型。基于DEFORM—3D有限元模拟软件，应用三维刚塑性有限元算法对直齿圆锥齿轮摆动辗压成形过程进行了模拟分析，得出变形中金属的流动状态和等效塑性应力应变分布规律，齿轮成形过程及等效应力—应变用图形、曲线直观表示出来，获得了摆动辗压成形金属变形规律。 结合齿轮成形规律，参照直齿圆锥齿轮摆辗成形生产经验，通过改变直齿圆锥齿轮摆动辗压的工艺参数的有限元模拟，分析探讨了下模进给量、摩擦系数和摆头倾角的改变量对凹模应力影响程度以及对凹模失效形式的影响分析，获得了模具在不同工艺参数下的应力对比曲线，直观而又深刻地揭示了摆动辗压工艺参数对模具的具体影响程度。 基于DEFORM—3D模具分析模块，对模具的失效形式及失效本质进行了更深层次的研究，通过对凹模任一齿形的齿根应力有限元模拟分析，得出了凹模齿根应力曲线，分析探讨了摆动辗压凹模齿根应力分布规律，总结了凹模齿形失效的本质原因。更多还原

【Abstract】 Rotary roll is a new technology that applied in partly presswork succession plasticity forming. The cold rotary forging used in straight tooth bevel gear is an advanced technique which used in gear processing. It has a good many merits, such as high material utilization, high productivity, low manufacturing cost, high gear mechanical property, high service life and high forming dimensional accuracy etc. It widely applied in gear processing.This thesis based on the research of the rotary forging in straight tooth bevel gear technology. Finite element analysis is employed to research the process of cool rotary forging in differential satellite gear. The statuses of strain and stress, metal flow rule and force-time curve are obtained and reveal the deformation characteristic. And the essence cause of the cavity die’s invalidation has been discussed.The straight tooth bevel gear’s rotary roll model has been created in three-dimensional molding software UG based on its prototype. The models which will be used in DEFORM-3D have been gotten. They’re the foundation of finite element analysis in straight tooth bevel gear’s rotary roll.The models of finite element analysis used in straight tooth bevel gear’s rotary roll have been created based on the rigid plasticity finite element theory. The statuses of strain and stress, metal flow rule have been gotten based on the three-dimensional simulation software DEFORM-3D by the use of rigid plasticity finite element analysis. The deformation process, equivalent stresses, equivalent strains are showed by figure and curve. And the deformation rulers have been gotten.Invalidation form of straight tooth bevel gear of rotary roll cavity die has been analyzed, and the finite element simulation method is employed to change the processing parameter of rotary roll. The effect of feed rate of cavity die, friction factor and inclination of rotary head on die stress and die invalidation form have been analyzed and discussed based on the manufacture experiences and finite element analysis. Stress contrastive curve in different processing parameter have been gotten.更多还原