【摘要】：齒輪是汽車(chē)與機(jī)械領(lǐng)域最常見(jiàn)的傳動(dòng)部件,絕大部分汽車(chē)與設(shè)備主要傳動(dòng)部件都采用的是齒輪傳動(dòng),直齒圓柱齒輪是齒輪傳動(dòng)中應(yīng)用最為廣泛的一種齒輪。直齒圓柱齒輪的加工方式目前主要采用傳統(tǒng)的切削加工,這不僅耗費(fèi)工時(shí),材料利用率低,成本也較高。在目前激烈的市場(chǎng)競(jìng)爭(zhēng)之下,傳統(tǒng)的加工方式已無(wú)法滿足低能耗高質(zhì)量的要求,而冷擠壓加工工藝由于其優(yōu)質(zhì)、高效、節(jié)能的顯著優(yōu)點(diǎn),開(kāi)始廣泛地應(yīng)用于直齒圓柱齒輪的加工中。在齒輪的冷擠壓成形過(guò)程中,模具承載著較大的單位擠壓力,凹模也受到較大的圓周拉應(yīng)力,即使三層組合凹模,模芯也極易破裂。直齒圓柱齒輪冷擠壓模具易破裂的問(wèn)題嚴(yán)重阻礙了冷擠壓技術(shù)在齒輪成形中的推廣應(yīng)用。因此,如何避免模具破裂,提高模具強(qiáng)度及壽命是目前研究齒輪冷擠壓成形技術(shù)的關(guān)鍵。本文以載重汽車(chē)用輪邊減速器直齒圓柱齒輪為研究對(duì)象,提出連續(xù)擠壓的冷擠壓工藝方案,并采用傳統(tǒng)經(jīng)驗(yàn)計(jì)算的組合凹模進(jìn)行冷擠壓成形數(shù)值模擬分析;基于均勻過(guò)盈量組合凹模的失效分析,提出變過(guò)盈量的設(shè)計(jì)方法,通過(guò)對(duì)該方法的研究,進(jìn)一步提出了組合凹模局部變過(guò)盈量設(shè)計(jì)方法,并對(duì)該方法進(jìn)行了深入的研究;采用響應(yīng)面法對(duì)組合凹模尺寸參數(shù)進(jìn)行優(yōu)化設(shè)計(jì),確立了合理的組合凹模尺寸參數(shù),充分的發(fā)揮了材料的性能;針對(duì)齒輪金屬流動(dòng)規(guī)律及模具應(yīng)力分布規(guī)律進(jìn)行分析,研究了各工藝參數(shù)對(duì)齒輪成形質(zhì)量、模具應(yīng)力及模具溫度的影響規(guī)律。根據(jù)有限元數(shù)值模擬結(jié)果,進(jìn)行了直齒圓柱齒輪的冷擠壓工藝試驗(yàn)及生產(chǎn)應(yīng)用,試驗(yàn)結(jié)果表明:冷擠壓加工的直齒圓柱齒輪成形質(zhì)量較好;模具擠壓次數(shù)達(dá)15萬(wàn)件后,模具使用情況良好,擠壓件公法線檢測(cè)長(zhǎng)度在設(shè)計(jì)要求范圍之內(nèi);變過(guò)盈量組合凹模的設(shè)計(jì)方法及組合凹模結(jié)構(gòu)參數(shù)的優(yōu)化設(shè)計(jì)可以提高模具的使用壽命。試驗(yàn)結(jié)果驗(yàn)證了數(shù)值模擬的準(zhǔn)確性。
[Abstract]:Gear is the most common transmission part in the field of automobile and machinery. Most of the main transmission parts of automobile and equipment are gear transmission. Spur gear is the most widely used gear in gear transmission. At present, the machining method of spur gear mainly adopts traditional cutting, which not only consumes man-hours, but also has low material utilization ratio and high cost. In the current fierce market competition, the traditional processing methods can no longer meet the requirements of low energy consumption and high quality, while the cold extrusion process has the remarkable advantages of high quality, high efficiency and energy saving. It has been widely used in the machining of spur gear. In the cold extrusion forming process of gears, the die bears a large unit extrusion pressure, and the die is subjected to larger circumferential tensile stress. Even if the three layers combined die, the die core is easy to break. The problem that the cold extrusion die of spur gear is easy to rupture seriously hinders the popularization and application of cold extrusion technology in gear forming. Therefore, how to avoid the die rupture and improve the die strength and life is the key to the research of gear cold extrusion forming technology. In this paper, the straight cylindrical gear of wheel side reducer used in truck is taken as the research object, and the cold extrusion technology scheme of continuous extrusion is put forward, and the numerical simulation analysis of cold extrusion forming is carried out by the combination die of traditional experience calculation. Based on the failure analysis of combined die with uniform interference, the design method of variable interference is put forward. Through the research of this method, the design method of local variable interference of combined die is put forward, and the method is studied deeply. The response surface method is used to optimize the dimension parameters of the combined die, and the reasonable dimension parameters of the combined die are established to give full play to the performance of the material. Based on the analysis of metal flow law of gear and stress distribution of die, the influence of various technological parameters on gear forming quality, die stress and die temperature is studied. According to the results of finite element numerical simulation, the cold extrusion technology test and production application of spur cylindrical gear are carried out. The results show that the forming quality of straight tooth cylindrical gear processed by cold extrusion is good. When the extrusion times of the die reach 150000, the working condition of the die is good, and the inspection length of the common line of the extruded parts is within the range of the design requirement. The design method of the combined die with variable interference and the optimum design of the structural parameters of the combined die can improve the service life of the die. The experimental results verify the accuracy of the numerical simulation.
【學(xué)位授予單位】：重慶理工大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2017
【分類(lèi)號(hào)】：U466;TG375.41

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