CN103990753B - 油泵齿轮轴精锻成形模具及成形方法 - Google Patents
油泵齿轮轴精锻成形模具及成形方法 Download PDFInfo
- Publication number
- CN103990753B CN103990753B CN201410219246.8A CN201410219246A CN103990753B CN 103990753 B CN103990753 B CN 103990753B CN 201410219246 A CN201410219246 A CN 201410219246A CN 103990753 B CN103990753 B CN 103990753B
- Authority
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- Prior art keywords
- mould
- counterdie
- forging
- tooth
- profile
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
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- 238000005242 forging Methods 0.000 title claims abstract description 52
- 238000004519 manufacturing process Methods 0.000 title abstract description 12
- 239000002184 metal Substances 0.000 claims abstract description 9
- 238000000034 method Methods 0.000 claims abstract description 6
- 238000003856 thermoforming Methods 0.000 claims abstract description 4
- 210000001331 Nose Anatomy 0.000 claims description 3
- 230000001939 inductive effect Effects 0.000 claims description 3
- 238000003754 machining Methods 0.000 abstract description 7
- 239000000463 material Substances 0.000 abstract description 3
- 239000003921 oil Substances 0.000 description 17
- 238000005516 engineering process Methods 0.000 description 3
- 238000005520 cutting process Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000005452 bending Methods 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N carbon Chemical compound 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Abstract
一种油泵齿轮轴精锻成形的模具结构及成形方法，属于齿轮轴的加工技术领域，提供了一种凹模分层式油泵齿轮轴精锻成形的模具结构及成形方法。模具结构主要包括上模，下模上层，齿形模具，下模下层，底座，下模外圈，压圈，脱模环八个部分，模具型腔分为三层，下模上层、齿形模具和下模下层，分别成形齿轮轴的两个侧轴和齿形。油泵齿轮轴精锻成形方法包括三个步骤，加热棒料，只加热成形齿形部分金属，即棒料中间段；精锻齿轮轴，一次性成形齿轮轴的上下侧轴及齿形；出模，锻造后将锻件和齿形模具分离。三个步骤即可完成油泵齿轮轴轴体及齿形的粗加工，加工效率高，节约材料，生产成本低；凹模分层的结构，结构紧凑，模具零件形状简单，加工成本低。
Description
技术领域
[0001]本发明属于齿轮轴的加工技术领域，提供了一种凹模分层式油栗齿轮轴精锻成形的模具结构及成形方法，用于油栗齿轮轴精锻生产。
背景技术
[0002]齿轮油栗广泛运用于液体输送和液压系统等装置中，油栗中的齿轮轴属于机械结构中常用的基础零件，齿轮栗齿轮通常不是标准齿轮，齿轮栗齿轮具有较大的变位系数和较高的齿顶高。为了适应齿轮栗体积紧凑，准配精度高的特点，齿轮栗齿轮一般是齿轮带轴整体加工。目前齿轮加工工艺一般首先热锻成形齿还，齿形则通过滚齿、插齿、剃齿和磨齿等切削工艺完成。采用切削工艺方法生产齿轮，加工时间长，生产效率低、生产成本高。同时切削加工会破坏金属的纤维组织，因而轮齿的弯曲疲劳强度、齿面接触疲劳强度与耐磨性、使用寿命等都会降低，并且切削加工材料利用率低，能耗高。
[0003]齿轮精锻是利用金属高温时良好的塑性使轮齿成形，即利用金属塑性变形的原理，按照金属压力加工成形方法制造轮齿。用锻造方法生产齿轮具有生产率高、节约材料、降低成本节能环保等特点，并且由于齿部金属流线连续，沿齿廓分布，齿轮强度高、寿命长等优点，因此齿轮精锻成形工艺是一种极具发展潜力的工业生产手段。
发明内容
[0004]本发明提供了一种凹模分层式油栗齿轮轴精锻成形的模具结构及成形方法，三个步骤即可完成油栗齿轮轴轴体及齿形的粗加工，加工效率高，节约材料，生产成本低；凹模分层的结构，结构紧凑，出模方便，模具零件形状简单，加工成本低。
[0005]本发明的技术方案是:一种油栗齿轮轴精锻成形模具，包括上模I，下模上层2，齿形模具3，下模下层4，底座5，下模外圈6，下模座7和脱模环8，其中上模I是一个简单的凸杆结构，装于压力机上滑块之下；下模上层2、齿形模具3和下模下层4构成模具型腔，其依次装于下模座7中；底座5置于下模下层4之下，下模座7由下模外圈6固定在压力机机座之上;脱模环8由螺母固定在下模外圈6之上。
[0006]其中上模I是一个简单的凸杆结构，主要作用是形成封闭模腔和传递锻造能量;下模上层2用于成形齿轮轴的一端侧轴，齿形模具3是用于成形齿轮轴的齿形部分，下模下层4用于成形齿轮轴的侧轴。底座5用于承载齿轮轴的成形压力，下模外圈6用于固定下模座，下模座7用于保证整套模具的定位精度和承载过多的锻压力，脱模环8用于防止锻造过程中卡料而产生的下模上层2被带起。
[0007]其中，模具型腔分为三层，下模上层2、齿形模具3和下模下层4，分别成形齿轮轴的两个侧轴和齿形，三层的形位精度由下模外圈7保证;下模上层2和齿形模具3为内外圈过盈装配组合而成，以对模具施加预紧力，防止模具在锻造过程中受力开裂而失效;齿形模具3的齿形可由线切割直接加工而成，加工简单，精度高，加工成本低；
[0008]本发明的另一个优选方案是上述的上模I与下模上层2之间有空隙，锻造过程中，若锻件金属流入上模I与下模上层2之间的空隙，下模上层2将锻造结束，即上模I抬起时，将被带起，这时脱模环8将下模上层2挡住，保证模具与锻件分离。
[0009] 一种利用如权利要求1所述油栗齿轮轴精锻成形模具加工齿轮轴锻件成形方法，其特征在于，包括以下三个步骤:
[0010]步骤1，加热棒料，将棒料放入感应加热炉中加热至1000°C至1100°C，并且只加热成形齿形部分金属，即棒料中间段；
[0011 ]步骤2，将棒料中间段放入油栗齿轮轴精锻模具中进行锻造，一次性成形齿轮轴的上下侧轴及齿形；
[0012]步骤3，锻造后，锻件将和齿形模具3紧密贴合在一起，将锻件和齿形模具3取出并移至另一工位，顶出齿轮轴锻件。
[0013]本发明的优点
[0014] I)本发明采用精密锻造方法加工油栗齿轮轴，可以代替传统切削加工中的粗加工，仅需三个步骤就可加工出油栗齿轮轴产品；
[0015] 2)与传统切削加工相比加工效率可提高10〜50倍，材料利用率可达到80%以上，提高20〜40个百分点，产品性能也有一定程度提高；
[0016] 3)采用凹模分层式结构，结构紧凑，解决了油栗齿轮轴精锻模具分模困难的问题，模具零件形状简单，加工成本低；
[0017] 4)采用多工位出模方式，解决了锻造后出模困难的问题。
附图说明
[0018]图1为本发明的油栗齿轮轴精锻模具总装图，其中:I为上模，2为下模上层，3为齿形模具，4为下模下层，5为底座，6为下模外圈，7为下模座，8为脱模环。
[0019]图2为模具中下模上层零件图。
[0020]图3为模具中齿形模具零件图。
[0021]图4为坯料加热段示意图。
[0022]图5为出模工位示意图，其中:3为齿形模具，9为顶杆，10为锻件，11为出模座。
[0023]图6为本发明精锻的油栗齿轮轴实例。
具体实施方式
[0024]如图6所示，本发明实例所锻造的油栗齿轮轴，包括齿形部分和两侧轴部分;下模下层高度等于齿轮轴侧轴高度，齿形模具高度等于齿轮轴齿形高度;齿形模具和下模下层均由内外圈过盈装配而成;模具各个部分按图1所示结构装配:上模I装于压力机上滑块之下，底座5、下模下层4、齿形模具3(图3)、下模上层2(图2)依次装入下模座7中，并由下模外圈6固定在压力机机座之上;脱模环8由螺母固定在下模外圈6之上。
[0025]本实例模具安装在1000T双盘摩擦压力机上进行油栗齿轮轴精锻加工，锻压速度约为200mm/s，锻造模具及锻件均涂抹水基石墨润滑剂。
[0026]本实例的油栗齿轮轴精锻成形包括以下三个步骤:
[0027]步骤1，加热棒料，如图4所示，将棒料放入感应加热炉中加热至1000°C至1100°C，只加热成形齿形部分金属，即棒料中间段；
[0028]步骤2，精锻，如图1所示，在本发明所述的油栗齿轮轴精锻模具中进行锻造，一次性成形齿轮轴的上下侧轴及齿形；
[0029]步骤3，出模，如图5所示，锻造后，锻件和齿形模具紧密贴合在一起，将锻件和齿形模具移至另一工位，顶出齿轮轴锻件。
Claims (2)
1.一种油栗齿轮轴精锻成形模具，其特征在于，油栗齿轮轴精锻成形模具包括上模(1)，下模上层(2)，齿形模具(3)，下模下层(4)，底座(5)，下模外圈(6)，下模座(7)和脱模环(8)，其中上模(I)是一个简单的凸杆结构，装于压力机上滑块之下；下模上层(2)、齿形模具(3)和下模下层(4)构成模具型腔，其依次装于下模座(7)中；底座5置于下模下层(4)之下，下模座(7)由下模外圈(6)固定在压力机机座之上;脱模环(8)由螺母固定在下模外圈(6)之上，其特征在于，所述的上模(I)与下模上层(2)之间有空隙，锻造过程中，若锻件金属流入上模(I)与下模上层(2)之间的空隙，下模上层(2)锻造结束，即上模(I)抬起时，下模上层(2)将被带起，这时脱模环(8)将下模上层(2)挡住，保证上模(I)与锻件分离。
2.—种利用如权利要求1所述油栗齿轮轴精锻成形模具加工齿轮轴锻件成形方法，其特征在于，包括以下三个步骤: 步骤1，加热棒料，将棒料放入感应加热炉中加热至1000°C至1100°C，并且只加热成形齿形部分金属，即棒料中间段； 步骤2，将棒料中间段放入油栗齿轮轴精锻成形模具中进行锻造，一次性成形齿轮轴的上下侧轴及齿形； 步骤3，锻造后，将齿轮轴锻件和齿形模具(3)紧密贴合在一起，将齿轮轴锻件和齿形模具(3)取出并移至另一工位，顶出齿轮轴锻件。
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