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The trial forming of a spur gear made from the drawn cup by plastic working

拉深杯塑性加工正齿轮的试制

基本信息

批准号：
12650126
负责人：
UCHIDA Yukihiko
金额：
$ 1.09万
依托单位：
Nihon University
依托单位国家：
日本
项目类别：
Grant-in-Aid for Scientific Research (C)
财政年份：
2000
资助国家：
日本
起止时间：
2000 至 2001
项目状态：
已结题

来源：
https://kaken.nii.ac.jp/grant/KAKENHI-PROJECT-12650126/
关键词：
Forging Divided flow forging Decrease of forming pressure Improvement of filling ratio Finite element method FEM 塑性加工鍛造平歯車成形荷重低減

项目摘要

In previous report, it was proposed that a new production method in which a spur gear was made from the drawn cup by plastic working. This forming method consists of four processes, namely drawing, re-striking, ironing and compressing process. However, the forming of steel gears isn't suitable for the actual production because the forming pressure in the compressing process is too high. And, filling ratio is not also enough. So, It is examined to reduce forming pressure and to improve filling ratio by two types of the divided flow forging method. One is how to flow material into the opposite side of tooth by using the cushion punch with grooves. The other is how to flow material into the clearance between the cushion punch and compressing plate which enlarged the bore. It is found that divided flow methods be able to improve of filling ratio and to reduce of forming pressure. Test materials are aluminum (A1050) and mild steel (SPHC). The FEM simulation was done by using deform3D-v3.3. A deformation mechanism by the FEM simulation is very similar to the experimental result, and it can estimate state of filling up in the tooth top and forming pressure. As a result, when a divided flow punch was used, the decrease rate of the forming pressure was 22.6%, and when the divided flow plate was used, the decrease rate of the forming pressure was 14.3%. It was found that divided flow method could improve of filling ratio and decrease of forming pressure and the effect of it wasn't based on materials. A deformation mechanism by the FEM simulation was very similar to the experiment result, and it was found that it could guess filling up of the tooth top and forming pressure.

在以前的报告中，有人提出了一种新的生产方法，即由拉伸杯形件通过塑性加工制造直齿圆柱齿轮。该成形方法由四道工序组成，即拉深、再敲击、拉深和压缩工序。然而，由于压缩过程中的成形压力太高，钢齿轮的成形并不适合实际生产。而且，充填比也不够。为此，研究了两种分流锻造方法在降低成形压力和提高充填率方面的应用。一种是如何使用带凹槽的缓冲冲头将材料流到牙齿的反面。另一种是如何将物料注入缓冲冲头和压板之间的间隙中，从而扩大了孔径。结果表明，分流方法可以提高充填率，降低成形压力。测试材料为铝(A1050)和软钢(SPHC)。利用Deform3D-v3.3软件进行了有限元模拟。有限元模拟得到的变形机理与实验结果非常接近，可以预测齿顶的充填状态和成形压力。结果表明，采用分流冲头时，成形压力下降率为22.6%，采用分流冲板时，成形压力下降率为14.3%。结果表明，分流法可以提高充填率，降低成型压力，且其效果与材料无关。有限元模拟得到的变形机理与实验结果非常接近，可以推测出齿顶的充填情况和成形压力。