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针对直齿锥齿轮冷成形工艺,采用塑性有限元法,对成形过程进行数值模拟,分析了各阶段坯料流动情况及产品卸载后的回弹规律。结果显示,在齿高方向,最小回弹在最大齿厚0.02mm处,沿齿顶或齿根逐渐增大,接近齿顶处回弹值达到最大为0.14mm。选用反补偿修正法对齿形凹模二次修正,获得满足所需精度的目标齿轮,最大偏差值为-0.025mm。研究表明,通过数值模拟回弹分析与修正,可以获得较高齿形精度的直齿锥齿轮产品,缩短了模具制造周期,降低了成本。
Aiming at the cold forming process of spur bevel gear, the plastic finite element method was used to simulate the forming process. The billet flow in each stage and the rebound rule after unloading were analyzed. The results show that in the tooth height direction, the minimum rebound at the maximum tooth thickness 0.02mm, along the addendum or tooth root gradually increases, near the addendum rebound value reaches a maximum of 0.14mm. Select the anti-compensation correction method for the secondary correction of the tooth-shaped concave mold to obtain the desired precision to meet the target gear, the maximum deviation of -0.025mm. The research shows that the straight bevel gear with higher profile accuracy can be obtained by numerical simulation of rebound analysis and correction, which can shorten the mold manufacturing cycle and reduce the cost.