齿形零件精冲成形三维有限元模拟与工艺优化

利用DEFORM-3D建立了三维精冲有限元模型,采用更新拉格朗日弹塑性有限元方法和基于应变梯度、表面曲率的网格自适应技术,对齿轮精冲的局部剧烈塑性变形进行了模拟.通过DEFORM用户子程序实现了Schiffmann损伤功密度的半耦合计算,分析了成形过程中静水应力、等效应力、等效应变和损伤的分布以及发展趋势,并预测了不同工艺参数下的精冲力和齿轮不同部位塌角高度、光亮带高度.利用模拟得出的最佳工艺参数获得了合格的齿形零件.

3D FEM Modeling of Gear Wheel Fine-blanking Forming and the Process Optimization

By using DEFORM-3D software,a 3D FE model of fine-blanking was created,and the updated Langrage elasto-plastic FEM and the adaptive remeshing technique based on strain gradient and surface curvature were used to simulate the localized severe plastic deformation.The Schiffmann damage work density model which considers the combination of plastic work of matrix and void growth work was integrated with DEFORM-3D,and it was used to predict the position and developments of damage and fracture.Furthermore,the cutting force and the heights of roll-over and clean-cut in different regions of gear wheel under different process parameters were predicted.In the end,qualified parts were obtained using the optimized process parameters from simulation.