圆柱齿轮热精锻成形载荷影响因素分析

研究圆柱齿轮热精锻成形载荷计算方法,在圆柱体闭式镦粗计算公式中引入齿形影响因子,得到齿轮热精锻成形载荷经验公式. 有限元仿真模拟了模数分别为1,2,3,4 mm圆柱直齿轮的热精锻过程,利用仿真得到的成形载荷数据拟合求得了齿形影响因子的计算公式;在该经验公式的基础上分析了锻件齿根圆直径、内孔径、高度、齿轮模数以及坯料材料流动应力对齿轮精锻成形载荷的影响;齿轮热精锻实验和文献中齿轮锻造成形载荷数据共同验证了公式的准确性和适用范围;通过变形的齿轮热精锻成形载荷经验公式,求出不同压力机可锻压齿轮的尺寸范围. 

Analysis of the Forming Load Impact Factors on Hot Precision Forging of Cylindrical Gears

A formula for calculating the forming load of gears in hot precision forging was studied. The formula of forming load for gear forging was deduced by introducing the tooth impact factor into the formula for forming load of closed upsetting. The formula for the tooth impact factor was fitted by the data got from FEM simulation of forging process, in which gears of module 1, 2, 3, 4 mm were forged. The effects of the following parameters on the precision forming load were analyzed based on the new forming load formula: the diameter of root circle and bore of the workpiece, the height of the workpiece, module and flow stress of the billet material. Some forging tests for gears were conducted and the data of forming load in literature was utilized to validate the validity of the formula, as well as the application scope. The formula was further deduced to calculate the dimension range of forged gears for the presses with different nominal pressure, which was of engineering significance.