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

为提高烧结铁合金齿轮的承载能力，本研究旨在开发超声振动精轧挤压复合加工系统。本研究取得的成果如下。超声振动挤压工艺对粉末冶金齿轮表层固结的影响不大，只有精轧才能获得足够承载能力和足够精度的齿轮。1)在轴交式成形滚压机上进行试验，量化了一些工艺参数与粉末冶金齿轮变形性能之间的关系。设定轧制量为0.15 mm或更大时，表层的固结程度可达到目标水平，轧制后试件的表面耐用度较未轧制试件提高一倍。2)利用螺旋…对修形后的粉末冶金齿轮进行了滚压试验形状更好的刀具，齿形不变。当工件节点处的凸度与刀具垂直于齿面的压痕深度相同时，滚压后的齿形几乎是平的。3)建立了螺杆刀具精轧粉末冶金齿轮的三维有限元模型。利用该有限元模型对修形后的齿形进行了优化，并利用螺旋刀进行了精轧试验。4)研制了一种轴交式数控滚压成型机，实现了工件的径向进给量与其轴向进给量的同步。利用该设备可以对齿轮的齿面进行特定的凸度加工。5)在双辊模直进给成形滚压机上进行成形轧制试验。并对其基本轧制特性进行了详细研究。该方法可使粉末冶金滚子和齿轮的表层固结达到与轴交型滚压试验相同的水平。6)采用二维有限元方法进行了数值齿形分析，分析结果与实验结果吻合较好。较少

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）。