重型汽车轮边减速器太阳轮冷挤压技术研究

发布时间：2018-01-28 18:47

本文关键词： 太阳轮冷挤压分步成形同步成形参数优化工艺试验　出处：《重庆理工大学》2017年硕士论文　论文类型：学位论文

【摘要】：太阳轮是行星齿轮传动机构中重要的零件,由于其结构复杂,加工要求高,目前主要还是采用传统的切削加工方法生产,即使运用冷挤压成形工艺加工太阳轮也是先成形外齿,然后再通过拉齿工艺加工出内花键。采用拉齿工艺等传统的切削加工方法,不可避免地存在着加工效率低、切削废料多、成本高,材料的力学性能降低等一系列问题。冷挤压技术是一种节能,高效,绿色的精密塑性成形方法,越来越多的企业选择冷挤压成形这种少无切削、节能环保的精密塑性成形技术来加工齿轮。但由于太阳轮同时具有外齿和内花键,形状复杂,成形困难;挤压过程中金属流动复杂,齿形部分的成形质量难以保证,这严重制约了冷挤压技术在类似齿轮加工中的推广应用。本文以具有外齿和内花键的太阳轮为研究对象,针对其结构特点和数值模拟分析结果确定了太阳轮内外齿分步冷挤压成形工艺方案。通过数值模拟分析得到了太阳轮成形过程中的金属流动规律和各工艺参数对成形质量及成形载荷的影响规律;采用弹塑性有限元模型对太阳轮的成形精度进行了研究,得到了模具弹性扩张和挤压件弹性回复行为对齿轮精度的影响规律,提出冷挤压+精整的复合成形工艺,并成形出较高精度的太阳轮外齿和内花键。根据数值模拟结果,进行了太阳轮内外齿分步冷挤压成形工艺试验。工艺试验表明,采用分步冷挤压成形工艺可以加工出质量合格的内花键和外齿,而且分步冷挤压成形工艺中增加了精整外齿的工艺,在保证内花键成形质量的同时提高了外齿的成形精度。为了满足企业进一步降低生产成本,提高生产效率的要求,提出了采用实心坯料同步冷挤压成形太阳轮内外齿的工艺方案;通过数值模拟分析得到了各工艺参数对太阳轮同步冷挤压成形的影响规律;通过正交实验设计的方法对各工艺参数进行了优化分析,获得了最佳工艺参数组合。
[Abstract]:Solar wheel is an important part of planetary gear transmission mechanism. Because of its complex structure and high processing requirements, the traditional cutting method is mainly used to produce solar wheel. Even if the sun wheel is processed by cold extrusion, the outer teeth are formed first, and then the inner spline is processed by the pull-tooth process. Traditional cutting methods such as pull-tooth technology are adopted. A series of problems inevitably exist, such as low processing efficiency, high cutting waste, high cost and low mechanical properties of materials. Cold extrusion technology is an energy-saving, efficient, green precision plastic forming method. More and more enterprises choose cold extrusion forming, which is a precision plastic forming technology with few cutting, energy saving and environmental protection, to process gears. However, because the sun wheel has both outer teeth and inner splines, the shape is complex and the forming is difficult. During the extrusion process, the metal flow is complicated, and the forming quality of the tooth shape is difficult to guarantee. This seriously restricts the application of cold extrusion technology in similar gear machining. In this paper, the sun wheel with outer teeth and internal spline is taken as the research object. According to its structural characteristics and numerical simulation results, the forming process scheme of the solar wheel was determined. Through the numerical simulation analysis, the metal flow law and the process parameters of the solar wheel forming process were obtained. The influence of forming quality and forming load; The forming accuracy of solar wheel is studied by using elastic-plastic finite element model, and the influence of die elastic expansion and elastic recovery behavior of extrusion parts on gear accuracy is obtained. A cold extrusion finishing compound forming process is proposed, and a high precision solar wheel outer tooth and internal spline is formed. The numerical simulation results are given. The experimental results show that the quality of inner spline and outer tooth can be obtained by the step cold extrusion process. In order to meet the need to further reduce the production cost, the process of finishing the outer teeth is added in the step cold extrusion process, which ensures the forming quality of the inner spline and improves the forming accuracy of the outer teeth at the same time. In order to improve the production efficiency, the technological scheme of forming inner and outer teeth of solar wheel by synchronous cold extrusion of solid billets is put forward. Through numerical simulation analysis, the influence of various technological parameters on synchronous cold extrusion forming of solar wheel is obtained. The optimum combination of process parameters was obtained by orthogonal experimental design.
【学位授予单位】：重庆理工大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：U466;TG376.3

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