文档介绍：华中科技大学
硕士学位论文
大模数直齿圆柱齿轮精密塑性成形技术研究
姓名:朱怀沈
申请学位级别:硕士
专业:材料加工工程
指导教师:夏巨谌
2011-01-09
华中科技大学硕士学位论文
摘要
大模数齿轮是机车车辆、重型卡车、重型机床等多种重载传动机械产品必不可
少的基础零件,其质量、性能、寿命直接影响整机的技术经济指标。开发新的大模
数直齿圆柱齿轮成形技术,来改变传统的切削加工生产方式,最大限度地减少能耗、
提高材料利用率,提高产品质量、降低生产成本,是目前我国塑性加工行业面临的
重要课题。
本文围绕低合金钢大模数直齿圆柱齿轮锻件温-冷复合精密成形新工艺,采用有
限元模拟和工艺试验相结合的方法,进行了一系列的研究工作,开发了直齿圆柱齿
轮温锻-冷精整成形工艺与模具。
分析了大模数直齿圆柱齿轮零件的形状和结构特点,以提高零件尺寸精度、表
面质量和模具使用寿命为前提,确定了温锻预成形-冷精整终成形的工艺方案,并制
定了加工工艺路线。然后建立刚粘塑性齿轮温锻有限元模型和弹塑性齿轮冷精整有
限元模型,采用 Deform-3D 软件分别对两步成形过程进行了有限元模拟,优化了温
锻预成形工艺方案与工艺参数,得到了齿面冷精整量与齿轮锻件的相对壁厚同回弹
量之间的变化规律,优化了直齿圆柱齿轮冷精整量的取值范围。
在工艺分析和有限元数值模拟的基础上设计了直齿圆柱齿轮温锻预成形模具和
冷精整模具,对工艺分析和模拟结果进行了试验验证,试验结果验证了所提出的温
锻-冷精整工艺方案的可行性和正确性,对大模数直齿圆柱齿轮精密成形的实际应用
具有重要的指导和参考意义。

关键词: 大模数直齿圆柱齿轮; 复合成形; 有限元; 温锻工艺; 冷精整; 回弹

I
华中科技大学硕士学位论文
Abstract
Spur gears with big modulus are key parts applied widely in the
automobile and heavy mechanical industry. The quality and life of the spur
gears directly affect the whole machine of the technical and economic
indicators. Developing a new forming technology to substitute for
conventional cutting process, minimize energy consumption, improve
material utilization rate and product quality, and reduce production costs is an
important issue for Plastic processing industry in our country.
In the paper, the study on the warm-posite precision forming
process of low-alloy steel spue gear was carried out by means of FEA and
experiments together with the related process and die was developed
essfully.
The structure and shape features of the spur gear with big modulus were
analyzed in detail. To improve the dimensional accuracy, surface quality and
die life in spur gear forming, a two-step forming process scheme including
warm-forging preforming and cold precision sizing was proposed and the
process plan was woked out. A three-dimensional rigid-viscoplastic finite
element for warm forging preforming and a three-dimensional elasto-plastic
finite element