【作者】 吴紫光；

【导师】 张驰；

【作者基本信息】 重庆工学院 ， 材料加工工程， 2008， 硕士

【摘要】 齿轮是机械传动的关键零部件,用途广、批量大,其加工方式主要有两种——机加工与塑性成形加工。采用机加工方法加工齿轮,存在材料利用率低,毛坯切削余量大,生产效率低,能源消耗多,环境污染严重,且由于毛坯锻造组织流线被切断而使产品力学性能降低;而塑性成形加工的方法具有高产、优质、节能、节材的特点,符合技术发展的潮流和方向,是先进机械零件制造技术之一。本文以差速器行星齿轮为研究对象,采用精密塑性成形技术——闭塞锻造的方法来成形该齿轮,在研究过程中,主要完成了以下几个方面的工作:(1)针对差速器行星齿轮的特点,制订加工工艺路线;(2)初步确定锻件的形状及凸模工作部分的形状;(3)利用有限元分析软件——Deform-3D对齿轮的成形过程进行仿真,分析利用模拟结果,对齿轮的成形工艺参数及模具型腔的设计进行优化;(4)由于在加工齿轮的过程中,模具会产生热变形及弹性变形,因此本文引进了当量线膨胀率的概念,对模具的齿形进行修正,为后面的模具制造提供理论依据;(5)在630吨液压机上,利用闭塞锻造模架,进行工艺试验,检验模拟分析的结果。通过研究发现,模拟结果可靠。因此,模拟技术可在实际生产中推广运用,以降低工业产品的研发周期。更多还原

【Abstract】 Gear is very important part to the mechanical transmission, it is used widely, and its manufacturing batch is very large. Gear can be manufactured in two ways, one is machining processing, the other is plastic forming. To mechanical processing, there is a lot of disadvantages to it, such as low material utilization coefficient and high energy-consumer, etc. What’s more important is that metal flow line of the billet would be cut off, and the mechanical property of the product would be reduced. However, to plastic forming, it can overcome the disadvantages of the machining processing, this manufacturing way has a lot of advantages, for example, the manufacture efficiency can be improved, and the quality of the product is very good, so the plastic forming accord with the trend of technology development.In this paper, Differential Planetary Gear is taken as a research object. Closed-die forging, which is one of the precision plastic forming technology, is used to manufacture the gear. During researching, following works have been finished:(1) According to the characteristics of the Differential Planetary Gear, manufacture process is established;(2) The shape of forgings and the shape of working dies are primarily confirmed;(3) Deform-3D has been used to simulate the forming process. Through the simulation, forming process can be visualized, and the result of simulation can be used to optimize the forming process parameters and the configuration of mould;(4) During the forming of the gear, a lot of heat and elastic distortion will be produced. Therefore, the concept of the equivalent linear expansion rate is introduced into, and the equivalent linear expansion rate is used to amend the gear mould;(5) Forming experiment is done by the moldbase of closed-die forging on the liquid press, whose power is 630 ton. Through the experiment, simulation result can be checked up. It’s found that simulation results is reliable on the research results. So, the technology of FEA is worthy of generalizing, in this way, the R&D time of new product can be reduced a lot.更多还原