本文選題：大模數(shù) + 齒輪�。� 參考：《北京科技大學(xué)》2016年博士論文

【摘要】：齒輪是機(jī)械的重要零件之一,其中大模數(shù)齒輪廣泛應(yīng)用于重工行業(yè),目前主要以切削加工制造為主,工序多,效率低。齒輪塑性成形工藝可以提高生產(chǎn)效率,保持齒部金屬流線連續(xù)性,提高齒輪強(qiáng)度及使用壽命。小模數(shù)、小直徑錐齒輪的精密模鍛成形及小模數(shù)花鍵冷軋成形技術(shù)已經(jīng)得到工業(yè)應(yīng)用,但大模數(shù)齒輪模數(shù)大、直徑大,鍛造成形載荷大且對(duì)模具要求苛刻。因此,本課題提出采用熱軋工藝對(duì)大模數(shù)齒輪近凈成形的關(guān)鍵技術(shù)進(jìn)行研究。利用Gleeble-1500D熱模擬實(shí)驗(yàn)機(jī)對(duì)SAE8620H齒輪鋼高溫變形行為進(jìn)行研究,得到其在高溫下的真應(yīng)力-應(yīng)變曲線。根據(jù)實(shí)驗(yàn)結(jié)果,建立了其材料本構(gòu)模型,該模型使用雙曲正弦函數(shù),同時(shí)考慮了應(yīng)變對(duì)本構(gòu)方程參數(shù)的影響,能夠較好描述該齒輪鋼熱變形下的流動(dòng)應(yīng)力-應(yīng)變關(guān)系,為大模數(shù)齒輪熱軋成形數(shù)值模擬提供材料模型數(shù)據(jù)。通過(guò)實(shí)驗(yàn)研究了加熱溫度和保溫時(shí)間對(duì)SAE8620H齒輪鋼奧氏體晶粒長(zhǎng)大的影響規(guī)律,并通過(guò)熱模擬試驗(yàn)研究了SAE8620H齒輪鋼在單向壓縮過(guò)程中變形溫度、應(yīng)變速率和變形量對(duì)奧氏體晶粒細(xì)化的影響規(guī)律,基于實(shí)驗(yàn)數(shù)據(jù)建立了其微觀組織演變模型。提出一種大模數(shù)齒輪熱軋成形工藝,分析了軋制成形過(guò)程中傳動(dòng)齒輪變側(cè)隙嚙合對(duì)軋輥、轉(zhuǎn)件相對(duì)運(yùn)動(dòng)關(guān)系的影響規(guī)律；建立了軋輥、軋件齒形參數(shù)間的關(guān)系,考慮熱脹等因素設(shè)計(jì)確定了軋輥齒形及坯料尺寸：利用DEFORM軟件建立了大模數(shù)齒輪熱軋成形有限元模型,仿真分析其成形過(guò)程,并通過(guò)實(shí)驗(yàn)獲得了大模數(shù)齒輪軋件,對(duì)比分析了大齒輪熱軋過(guò)程中軋制力的變化規(guī)律。采用有限元方法研究了齒形長(zhǎng)起過(guò)程中金屬流動(dòng)規(guī)律；分析了齒形兩端填充不滿產(chǎn)生的原因以及工藝參數(shù)對(duì)齒形兩端填充的影響規(guī)律,提出凹形坯料設(shè)計(jì)方法補(bǔ)償齒形兩端填充,通過(guò)有限元和實(shí)驗(yàn)相結(jié)合的方法驗(yàn)證了補(bǔ)償措施的有效性：分析了軋輥軋件齒廓間相對(duì)滑動(dòng)對(duì)齒形拉尖形成的影響,仿真分析了工藝參數(shù)對(duì)齒形拉尖程度的影響規(guī)律,在仿真和實(shí)驗(yàn)過(guò)程中通過(guò)提高成形溫度、減小接觸摩擦系數(shù)并通過(guò)軋輥齒根壓整作用消除了拉尖現(xiàn)象。研究了大模數(shù)齒輪軋件精度影響因素,建立了內(nèi)孔偏差產(chǎn)生齒距偏差和齒廓形狀偏差的數(shù)學(xué)模型,分析了內(nèi)孔變化尺寸對(duì)齒距偏差和齒廓形狀最大偏差的影響規(guī)律；建立了軸彎曲變形產(chǎn)生齒廓形狀偏差和齒形齒向偏差的數(shù)學(xué)模型,分析了軋制力和軸直徑對(duì)齒廓形狀最大偏差和齒形齒向偏差的影響規(guī)律。通過(guò)測(cè)量軋件齒形精度得到：軋件單個(gè)齒距偏差、齒向偏差、徑向跳動(dòng)偏差達(dá)到12級(jí),齒廊形狀偏差超出12級(jí)精度55.9μm,累積齒距偏差超差較大。對(duì)比測(cè)量偏差和計(jì)算偏差,齒距累積總偏差計(jì)算結(jié)果和實(shí)驗(yàn)結(jié)果吻合較好,計(jì)算齒廓形狀偏差為67.4μm,排除偏差影響因素,齒廊形狀精度可以達(dá)到12級(jí)。調(diào)用SAE8620H齒輪鋼微觀組織演變模型,編寫微觀組織演變子程序,借助有限元仿真技術(shù)分析了熱軋大模數(shù)齒輪齒部晶粒尺寸分布規(guī)律：并研究了軋制溫度、進(jìn)給速度和軋輥轉(zhuǎn)速對(duì)熱軋大模數(shù)齒輪齒部微觀組織演變規(guī)律的影響：對(duì)比實(shí)驗(yàn)和仿真軋件觀測(cè)點(diǎn)晶粒尺寸,晶粒尺寸平均誤差11.7%,證明了所建立微觀組織模型的可靠性,對(duì)工藝實(shí)踐具有指導(dǎo)意義。
[Abstract]:Gear is one of the most important parts of machinery, of which large modulus gear is widely used in heavy industry. At present, it is mainly based on cutting and manufacturing, with many working procedures and low efficiency. The plastic forming process of gear can improve production efficiency, keep the continuity of metal flow line, improve gear strength and service life. Small modulus, small diameter bevel gear. Dense die forging and small modulus spline cold rolling have been used in industrial application, but large modulus gear has large modulus, large diameter, large forging load and strict requirement to die. Therefore, the key technology of hot rolling process for near net forming of large modulus gear is studied in this paper. The Gleeble-1500D thermal simulation test machine is used for S The high temperature deformation behavior of AE8620H gear steel is studied and its stress-strain curve is obtained at high temperature. According to the experimental results, the constitutive model of the material is established. The model uses the hyperbolic sine function and the influence of the strain on the constitutive equation. It can describe the flow stress and strain under the hot deformation of the gear steel. The effect of heating temperature and holding time on the austenite grain growth of SAE8620H gear steel was studied by experiments. The deformation temperature of SAE8620H gear steel in the unidirectional compression process was studied by thermal simulation test, and the strain rate and deformation amount of austenite should be applied to the austenite. The influence rule of grain refinement is set up based on the experimental data. A hot rolling process of large modulus gear is put forward. The influence law of the gear gear gap meshing on the relative motion relationship of the roll and part in the rolling process is analyzed. The relationship between the roll and the parameters of the gear shape is established, and the heat expansion is considered. The shape of roll tooth and the size of blank are determined by the same factor design: the finite element model of large modulus gear hot rolling is set up by DEFORM software, the forming process is simulated and analyzed, and the large modulus gear piece is obtained by the experiment. The change law of the rolling force in the hot rolling process of the large gear is compared and analyzed. The tooth shape is studied by the finite element method. The law of metal flow in the long process of metal flow; analysis of the causes of the discontent of the teeth at both ends of the tooth and the influence of the process parameters on the filling of the teeth at both ends of the tooth; the concave blank design method is proposed to compensate the filling of the teeth at both ends, and the effectiveness of the compensation measures is verified by the combination of the finite element method and the experimental method: the profile of the roll piece is analyzed. The influence of relative sliding on the formation of tooth profile is simulated. The influence of process parameters on the tooth profile is simulated and analyzed. In the process of simulation and experiment, the drawing temperature is improved, the contact friction coefficient is reduced and the pulling tip is eliminated through the roller tooth root pressing. The influence factors of the precision of the large modulus gear piece are studied, and the influence factors of the precision of the large modulus gear piece are studied. The mathematical model of the deviation of the tooth distance and the profile of the tooth profile is produced by the inner hole deviation. The influence of the size of the inner hole on the deviation of the tooth distance and the maximum profile of the tooth profile is analyzed. The mathematical model of the shape deviation of the tooth profile and the deviation of the tooth profile is established, and the maximum deviation of the tooth profile shape and the diameter of the rolling force and the shaft diameter is analyzed. The influence rule of tooth profile deviation is obtained by measuring the tooth profile accuracy of rolling parts: single tooth distance deviation, tooth direction deviation, radial runout deviation to 12 grade, tooth Gallery shape deviation exceeding 12 grade precision 55.9 mu m, cumulative offset deviation of tooth distance greater. Comparison measurement deviation and calculation deviation, calculation result and experimental result of cumulative total deviation of tooth distance The shape deviation of the tooth profile is 67.4 m, and the shape accuracy of the tooth gallery can reach 12. The microstructure evolution model of the SAE8620H gear steel is called, the microorganization evolution subprogram is compiling, and the grain size distribution law of the number tooth gear part of the hot rolling large mould is analyzed with the aid of the finite element simulation technology. The influence of temperature, feed speed and roll speed on the microstructure evolution of hot rolled large modulus gear teeth: the contrast experiment and the grain size of the simulated workpiece observation point, the average grain size error of 11.7%, proved the reliability of the established microstructure model, and has the guiding significance for the process practice.
【學(xué)位授予單位】：北京科技大學(xué)
【學(xué)位級(jí)別】：博士
【學(xué)位授予年份】：2016
【分類號(hào)】：TG61;TG335.11

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