齿轮精密锻造技术发展.pdf

齿轮精密锻造技术的发展 胡忠民 QinetiQLimited(英国) 摘要:本文重点介绍近年来英国在齿轮精密锻造技术领域内的新进展。伯明翰大学机械工程 学院刚完成了一项为期三年的研究课题:圆柱直齿轮和斜齿轮精密锻造。该课题由英国工程 科学研究协会(EPSRC)资助，与英国的七家企业进行了合作，它在多年研究和实践的基础 上，进一步探讨齿轮锻造的机理，利用现代的分析手段，如计算机模拟和设计，旨在建立一 种生产和经济上可行的加工方法，制造出在齿形上不在需要加工的精密齿轮。 该项目研究和试验了圆柱直齿轮、圆柱斜齿轮和同步齿轮等三种汽车用齿轮。制造工艺 采用温锻加冷处理，用有限R4拟来分析锻造过程和设计模具，从而保证齿轮的精度.经过 三年的研究，己掌握其基本技术，下一步将进行工厂现场试验。 关键词:齿轮:精密锻造;计算机模拟:模具设计趟 DevelopmentoftheNet-shapeForgingTechnologyofGears HuZhongmin QinetiQLimited FutureSystemsTechnology,CodytechnologyPark,GriffithBuilding IvelyRoad,Famborough,Hampshire,GU14OLX,UK Abstract Thispaperdescribessomeaspectsofthedevelopmentofacommerciallyviableformingroutefor themanufactureofnet-shapegearforms.Thecriticalfeaturesofthemanufacturingmethodarethat itshouldbelowcostandhavehighproductivity.Thusthedevelopmenthasbeenbasedonsingle actingpresses,withonlyoneramandahighstrokingrate.Theaimoftheworkistoproducenet- shapeonlyonthegearformasitisconsideredthatthemosteconomicmethodforproducingother featuresonconventionalgearsisbynearnet-shapeformingfollowedbymachining.Theworkis sponsoredbyEPSRC(UK)andsevenUKindustrialpartnersincludinggearusers,forgers,die manufacturersandsteelmakers.Theprojectconcenrtatedonautomotivegearboxgears.Thesizeand geometryofthistypeofgearlargelyprecludescoldforgingasthesoleproductionprocessaspress capacityandtoolsrtesseswouldbetoogreat.Theformingsequencechosenis;warmforging,to obtainanear-netshapeenvelope,followedbyacoldsizingoperation.Thecrucialfactorenabling gearteethtobeformednet-shapeisthecoldfinishingdie.Thishasbeendesignedusinghigh resolutionFEanalysiscontainingdetailedinformationofelasticdistortionsinbothdieand workpiece. ItisdemonsrtatedthatsatisfactorycoldfinishingdiescanbedesignedandthatgearteethtoISO5 standardcanbeformed.Thecomplexityofthecoldfinishingdieandtheultrahighaccuracyto whichitmustb