Workpiece-Tool-Interaction in the Fine Blanking of Helical Gears

精冲是为了经济地生产对被剪切表面和工件的几何公差有很高质量要求的板材零件而进行的一种剪切工艺。通过增强刀具运动学，这些优势已成功地应用于申请人与行业合作伙伴的斜齿轮生产中。实验表明，由于剪切边的质量和精冲齿轮的几何精度存在缺陷，将传统的工艺知识传授给新的运动学知识并不足以保证令人满意的加工质量。这些缺陷主要是由于与传统精冲相比，在旋转精冲过程中，工件内部的材料流动以及工具加载和偏转的改变。这两个方面都是由刀具几何形状、V形环压力和反冲力以及V形环的位置和几何形状作为最重要的工艺参数决定的。在本项目中，研究了上述因素对工件质量的影响，重点研究了刀具偏转和工件内部材料流动之间的相互作用。开发的工艺模型解释了斜齿轮回转精冲中决定工件质量的因果链，从而实现了基于知识的工艺设计。

Fine blanking is a shearing process for the economic production of sheet metal parts with high quality requirements concerning the sheared surfaces and the geometric tolerances of the workpiece. Enhancing the tool kinematics, these advantages have been successfully applied to the production of helical gears by the applicant, together with an industry partner. Experiments showed that transferring the conventional process know-how to the new kinematics is not sufficient to guarantee a satisfying workpiece quality, since deficits occur concerning the quality of the sheared edges and the geometric precision of the fine blanked gears. These deficits are mainly due to an alteration of the material flow inside the workpiece as well as of tool loading and deflection during the rotational fine blanking process compared to conventional fine blanking. Both aspects are strongly determined by the tool geometry, the V-ring force and the counterpunch force as well as by the position and the geometry of the V-ring as most important process parameters. In this project the influence of the factors named above on workpiece quality is investigated with a focus on the interactions between tool deflection and material flow inside the workpiece. The developed process model explains the cause-and-effect chains determining workpiece quality in the rotational fine blanking of helical gears and thus enables a knowledge based process design.