Development of Combination Processing System of Finish Rolling and Extrusion with Ultrasonic Vibration for Improving the Load Carrying Capacity of Sintered Fe Alloy Gears

提高烧结铁合金齿轮承载能力的精轧挤压超声振动复合加工系统的研制

• 批准号: 12555034
• 负责人: TAKEMASU Teruie
• 金额: $ 8.38万
• 依托单位: Kyushu University
• 依托单位国家: 日本
• 项目类别: Grant-in-Aid for Scientific Research (B)
• 财政年份: 2000
• 资助国家: 日本
• 起止时间: 2000 至 2003
• 项目状态: 已结题
• 来源: https://kaken.nii.ac.jp/en/grant/KAKENHI-PROJECT-12555034/
• 关键词: Powder Metallurgy; Gear; Finish Rolling; Consolidation; High Strength; High Precision; Numerical Control; Crowning; 超音波振動; 押出し; 複合加工システム; ローラ

The purpose of this study is to develop the combination processing system of finish rolling and extrusion with ultrasonic vibration to improve the load carrying capacity of sintered Fe alloy gears. The results obtained in this study are as follows. Extrusion process with ultrasonic vibration does not have a drastic effect on the consolidation of the surface layer of P/M gear teeth, arid the gears with enough load carrying capacity and enough precision can be obtained only by finish rolling.1)The relationship between some processing parameters and deformation properties of P/M gears are quantified from the experiments using the form rolling machine of axis intersection type. The target consolidation level in the surface layer can be attained by setting the amount of stock rolled 0.15mm or more, and the surface durability of the rolled specimens becomes doubled compared with the unrolled ones.2)The rolling experiments of P/M gears with modified tooth profile are carried out by the screw- … More shaped tool with unmodified tooth profile. The tooth profiles after rolling become almost flat when setting the amount of convex near the pitch point of the workpiece to the same as the depth of indentation of the tool normal to the tooth surface.3)3 dimensional Finite Element model is developed to simulate the finish rolling process of P/M gears using the screw-shaped tool. The finish rolling experiments are conducted using the screw-shaped tool with the modified tooth profile optimized by this FEM model. Gears with a good tooth profile and a good surface finish can be obtained.4)A numerical-control form-rolling machine of the axis intersection type is developed in which the amount of radial feed of the workpiece is synchronized with its axial feed. We can put a specified crowning on the gear teeth using this equipment.5)Form rolling experiments using the form rolling machine of 2 roller dies plunge feed type. are conducted and the basic rolling characteristics are examined in detail. The consolidation in the surface layer of P/M rollers and gears in this method can be attained to the same level as those in rolling experiments of the axis intersection type.6)The numerical tooth profile analysis is done using the 2 dimensional Finite Element Method and the analytical results agree well with the experimental ones. Less

本研究旨在开发超音波振动精轧挤压复合加工系统，以提高烧结铁合金齿轮的承载能力。本研究获得的结果如下。超声波振动挤压工艺对粉末冶金齿轮齿面表层的强化作用不大，只有精轧才能获得具有足够承载能力和精度的齿轮。1）在轴相贯式成形滚压机上进行试验，定量研究了部分工艺参数与粉末冶金齿轮变形性能的关系。当坯料的轧制量大于0.15mm时，表层的目标固结度达到了0.15mm，轧制后的试件的表面耐久性比未轧制的试件提高了一倍。 ...更多信息 未修改齿廓的成形工具。当工件节点附近的凸度与刀具垂直于齿面的压入深度相同时，滚轧后的齿廓基本平坦。3）建立了螺旋形刀具精轧粉末冶金齿轮过程的三维有限元模型。利用该有限元模型优化出的修形齿形进行精轧实验。4）研制了一种轴向进给量与径向进给量同步的轴相贯式数控成形滚压机。利用该设备可以在齿轮齿上进行特定的凸度加工。5）在双辊模切入式成形滚压机上进行成形滚压实验。并详细研究了基本轧制特性。该方法可使粉末冶金轧辊和齿轮的表层固结达到与轴线相贯式轧制试验相同的水平。6）采用二维有限元法对齿轮齿形进行了数值分析，分析结果与试验结果吻合较好。少

项目成果

竹増光家 et al.: "軸交差式仕上げ転造プロセスの三次元FEM解析"第9回機械材料・材料加工技術講演会. 149-150 (2001)

取Masumitsuya等人：“交叉轴精加工轧制过程的三维有限元分析”第9届机械材料与材料加工技术讲座149-150（2001）。

竹増光家 et al.: "Form Rolling for Finishing Powder Metal Gears"Gear Solutions. February. 32-39 (2004)

Takemasumitsuya 等人：“粉末金属齿轮精加工的滚压”齿轮解决方案，2004 年 2 月。

T.Takemasu: "Crowning Process of P/M Gears for Automotive Transmissions by Finish Rolling Using Screw-Shaped Tool"Proceedings of JSME/ASME International Conference on Materials and Processing. Vol.1. 533-538 (2002)

T.Takemasu：“使用螺旋形工具精加工汽车变速器 P/M 齿轮的冠冕工艺”JSME/ASME 国际材料与加工会议论文集。

T.Takemasu: "Crowning Process of P/M Gears for Automotive Transmissions by Finish Rolling Using Screw-Shaped Tool"Journal of the Japan Society for Technology of Plasticity. Vol.45-No.517. 118-122 (2004)

T.Takemasu：“通过使用螺旋形工具精轧的汽车变速器 P/M 齿轮的冠状加工”日本塑性技术学会期刊。

穂屋下茂 et al.: "鉄系焼結合金の面圧強度向上に関する研究(第1報,バニシ転造の効果)"日本機械学会九州支部講演論文集. 25-26 (2000)

Shigeru Hoyashita等人：“提高铁基烧结合金的表面压力强度的研究（首次报告，抛光轧制的效果）”日本机械工程师学会九州分会会议记录25-26（2000年）。