CN109926533B - Precision plastic forming method of bevel gear - Google Patents
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Abstract
The invention discloses a precise plastic forming method of a bevel gear, and belongs to the technical field of metal plastic forming. The method comprises the following steps: obtaining the characteristic parameters of the bevel gear precision forging; obtaining wave line parameters of the large end and the small end of the bevel gear fine forging piece according to the characterization parameters; manufacturing a pre-forging die according to the wave line parameters; putting the cylindrical blank into the pre-forging die for closed die forging to obtain a preformed piece; and placing the preformed piece into a finish forging die to carry out blocking upsetting extrusion forming on the tooth-shaped part, thereby obtaining the bevel gear finish forging piece with the complete tooth shape. The invention improves the metal filling capacity, reduces the metal filling load requirement, reduces the stress of the die and prolongs the service life of the die.
Description
Technical Field
The invention belongs to the technical field of metal plastic forming, and particularly relates to a precise plastic forming method of a bevel gear.
Background
Bevel gears can realize the transmission with crossed axes, and are widely applied to transmission systems of automobiles, machinery and machine tools. The traditional manufacturing method is to adopt a bar blank or a die forging blank, and then carry out cutting processing on the tooth shape by a copying milling method, a generating gear shaping method and the like. The bevel gear is produced by cutting processing, and tooth-by-tooth forming is needed, so that the production efficiency is low, and the material utilization rate is low; and the cutting process cuts off the metal streamline of the bar billet or die forging billet obtained by rolling, thereby reducing the fatigue resistance and the service life of the bevel gear.
The plastic forming method is characterized in that a press is used for forcing metal to flow in a die to obtain a high-precision tooth shape, and the bevel gear obtained by a precision forging process not only can fully utilize materials and has high production efficiency, but also avoids cutting metal fibers by cutting, and metal flow lines are distributed along the tooth profile, so that the fatigue resistance of the bevel gear produced by cutting is greatly improved compared with that of the bevel gear produced by cutting. Therefore, the precision plastic forming method of the bevel gear is widely applied, and the closed forging process is widely applied at home and abroad at present.
When the closed forging process is used for producing the bevel gear, metal flows in a closed cavity formed by a male die and a female die. Because the shape of the bevel gear is greatly changed in the radial direction and the axial direction, the adoption of the cylindrical blank for direct finish forging often causes uneven flow of metal to all parts of a die cavity, so that tooth form filling is incomplete. The tooth shape filling can be improved by increasing the load of the press, but the metal deformation exceeds the limit, the forge piece cracks along the tooth direction, the stress of the die is increased, and the service life is reduced sharply.
The addition of the preformed piece can pre-form the cylindrical blank into a shape close to that of a final forging piece, and when the preformed piece is placed into a final forging die for forming, the metal flow distance is short, the deformation is uniform, the filling is full, the product quality of the bevel gear forging piece can be effectively improved, and the service life of the die is prolonged. Although a pair of dies and equipment are added, the bevel gear forging with high precision can be obtained, and the tooth surface can be applied only by grinding, so that the method is an effective forming process.
The design of the preform shape is a difficulty with the above process. The shape of the preform is ensured both by the feasibility of forming the preform from a cylindrical blank and by the filling capacity of the preform when it is placed in a finish forging die. It is therefore desirable that the preform be of simpler shape while at the same time approaching the final forging. For bevel gear parts, the section of the tooth profile along the radial direction is constantly changed, and the tooth tops and tooth roots which have periodic periods along the axial direction fluctuate, so that the product shape is complex. The design of the preform is currently performed empirically and there is no systematic and complete design method.
The invention of publication No. CN102563010B provides a precision forging method and a die punch for a bevel gear with an inner hole having a symmetrical inner round head flat keyway structure, and provides a precision forging process after pre-forming, wherein a pre-forming piece is directly designed into a tooth-shaped blank, and the tooth-shaped precision is improved by rough forming, shot blasting and precision forming. The method has no effect on the flow filling of metal and the improvement of the stress condition of the die, and only adds a key groove positioning pit on the preformed piece so as to facilitate the accurate positioning of the blank during the fine forming.
The invention with publication number CN107252829A provides a precise near-net forming process and device for a bevel gear shaft, and provides a preliminary preformed cone blank according to the tooth taper angle and the shaft step shape of the bevel gear shaft. The conical part of the cone blank is determined according to the tooth cone angle of the bevel gear shaft, and the influence of the different sections of the large end and the small end of the bevel gear on the metal flow during forming is not considered, so that more metal flows in the radial direction, and the stress of the die and the abrasion of the die are increased. In the invention, the inward and outward flow of metal is controlled by arranging the air-permeable flow-dividing holes, and the diameters of the air-permeable flow-dividing holes are obtained according to experience. Too large results in under-filling of the bevel gear and too small results in cracking of the die. The preform also does not take into account the periodic relief features of the bevel gear finish forgings about the axial direction.
The formula for calculating the involute tooth profile sectional area is given by Shuqifuang, pool loyalty, Chenxiang, Shwen wisdom, Wutaibin, Chengwei and the like, the gear tooth area at any pitch cone can be calculated, and the formula can be used as a basis for designing the shape of the pre-forged blank. But the formula is established in a direction perpendicular to the pitch cone direction rather than in a radial direction of the gear, the formula is complex and inconvenient to apply, and only the sectional area of a tooth-shaped part is taken into consideration, and the shape of the gear except for the gear teeth is not considered.
Disclosure of Invention
Aiming at the defects of the prior art, the invention aims to provide a precision plastic forming method of a bevel gear, which aims to solve the problems of the prior art that the shape design of a preformed piece of the bevel gear is empirical, the forming is unstable, the filling is not uniform, the precision of a forged piece is low, the service life of a die is short and the like, and realizes the precision plastic forming of the bevel gear.
In order to achieve the purpose, the invention adopts the following technical scheme to realize the purpose:
a method of precision plastic forming of bevel gears, the method comprising the steps of:
obtaining the characteristic parameters of the bevel gear precision forging;
obtaining wave line data and a guide line through the characterization parameters;
manufacturing a pre-forging die according to the wavy line data and the guide line;
and putting the cylindrical blank into the pre-forging die for closed die forging to obtain a preformed piece.
Further, the characterization parameters comprise tooth number, big end module, tooth width and taper angle.
Further, the wavy line data comprise a wavy radius corresponding to the large tooth-shaped end of the bevel gear precision forging, a wavy height corresponding to the large tooth-shaped end, a wavy height corresponding to the large gear end, a wavy radius corresponding to the small tooth-shaped end, a wavy height corresponding to the small tooth-shaped end and a wavy height corresponding to the small gear end.
Further, the corresponding wave-shaped radius at the big end of the tooth shape is obtained by the following formula: r ise＝(me×z+2×ha×cosδ)/2-Δ；
The corresponding wave height at the big end of the tooth shape is set as h e0; the corresponding wave height at the big end of the gear is 0 to (h)a+hf)/2；
The corresponding wave radius at the small end of the tooth shape is as follows:
ri＝re-b×sinδ；
the corresponding wave height at the small end of the tooth shape is set as follows:
hi＝he+b×cosδ
the corresponding wave height at the small end of the gear is as follows:
0～[ha-b×sin(δa-δ)+hf-b×sin(δ-δf)]/2；
wherein m iseLarge end modulus, z is the number of teeth of the bevel gear, haIs the tooth crest height, delta is the taper angle, deltaaAt tip angle, δfIs root angle, b is tooth width, hfThe tooth root is high, delta is a single-side gap for placing the preformed piece into a finish forging die, and the distance is 0.5-1 mm.
Further, the guide wire obtaining method includes:
calculating the cross-sectional areas of the bevel gear finish forging at a plurality of positions along the radial direction;
converting the area of the cross section into height according to the cylindrical surface, and connecting height points of all radial positions;
and correcting the height points to obtain guide lines of the preformed piece, which correspond to the bevel gear finish forgings in the radial direction one by one.
Further, the manufacturing method of the pre-forging die comprises the following steps:
acquiring a three-dimensional space coordinate value of a wave line;
in three-dimensional space, taking the large-end and small-end wave lines as cross sections, and scanning by a guide line to obtain an upper surface graph of the preformed piece;
preparing a pre-forging die according to the upper surface pattern of the pre-forming piece.
Further, the three-dimensional space coordinate value of the wavy line is calculated by the following formula:
Xt＝r×cosθ
Yt＝r×sinθ
Zt＝hw×sin(θ×z)+h
in the formula, Xt, Yt and Zt are coordinate values of X, Y and Z coordinate directions of a wave line in a three-dimensional space under given parameters respectively, r is a wave radius, hw is a wave height, theta is 0-360 degrees, Z is the number of bevel gear teeth, and h is the wave height.
Furthermore, the radial dimension of the preformed piece is 0.5-1 mm smaller than that of the bevel gear precision forging piece.
Further, from the central shaft to the small tooth-shaped end, the ratio of the cross-sectional areas of the cylindrical surfaces of the preformed piece and the bevel gear precision forging piece at any radial position is 1: 1;
from the small end of the tooth profile to the middle point of the tooth width, the ratio of the cross sections of the cylindrical surfaces of the preformed piece and the bevel gear precision forging piece at any radial position is (1-1.05): 1 is linearly changed to 1: 1;
from the middle point of the tooth width to the large end of the tooth shape, the ratio of the cross sections of the cylindrical surfaces of the preformed piece and the bevel gear precision forging piece at any radial position is 1: 1 is linearly changed to (1-1.05): 1.
further, the method further comprises: and placing the preformed piece into a finish forging die to carry out blocking upsetting extrusion forming on the tooth-shaped part, thereby obtaining the bevel gear finish forging piece with the complete tooth shape.
Further, the cross section area A of the cylindrical surfaces of the preformed piece and the bevel gear precision forging piece at any radial position is outward in the radial direction from the central shaft of the bevel gearrOne-to-one correspondence is realized; in the axial direction of the bevel gear, the cylindrical section of the preformed part at the tooth-shaped part has a wave shape.
Further, according to the formula hp＝Ar/(2πrp) Calculating the radial direction as rpAverage height h of the surface of the preformpDrawing a guide line after correction;
further, the preformed piece corresponds to each tooth of the fine forged piece of the bevel gear.
Compared with the prior art, the invention has the beneficial effects that:
(1) acquiring the section areas of cylindrical surfaces at each position in the radial direction by a three-dimensional model design method of a preformed piece and utilizing three-dimensional modeling software according to the established bevel gear precision forging model, and establishing a radial guide line; in the axial direction, a wavy line formula is given, parameters such as the number of teeth, the large-end modulus, the tooth width and the like of the bevel gear precision forging piece are directly substituted, large-end wavy lines and small-end wavy lines can be directly obtained, and then a preformed three-dimensional model is established according to the large-end wavy lines, the small-end wavy lines and a guide line, so that the method is simple and easy to use;
(2) the addition of the preformed piece can pre-form the cylindrical blank into a shape close to that of a final forging piece, when the preformed piece is placed into a final forging die for forming, the metal flow distance is short, the deformation is uniform, the filling is full, the product quality of the bevel gear forging piece can be effectively improved, the service life of the die is prolonged, although a pair of die and equipment are added, the high-precision bevel gear forging piece can be obtained, and the tooth surface can be applied only by grinding, so that the forming process is effective;
(3) according to the invention, through the design of the preformed piece, the metal volume distribution of the preformed piece is consistent with the volume of the final bevel gear precision forging piece in the radial direction, metal mainly flows and deforms along the axial direction during finish forging, the pre-distribution of the tooth-shaped part is completed in the axial direction, the difficulty of fully filling the tooth shape and the metal flowing distance during finish forging are reduced, the precision forging metal flowing distance of the bevel gear is short, the metal flowing resistance is effectively reduced, the metal filling capacity is improved, the metal filling load requirement is reduced, the stress of a die is reduced, and the service life of the die is prolonged.
Drawings
FIG. 1 is a schematic illustration of a bevel gear finish forging;
FIG. 2 is a schematic cross-sectional view of a cylindrical surface of a bevel gear finish forging at any radial position;
FIG. 3 is a schematic representation of a cylindrical surface cross-section of a bevel gear finish forging at multiple radial locations;
FIG. 4 is a schematic illustration of a bevel gear preform surface design including large and small end wave lines, radial guide lines;
FIG. 5 is a design parameter for the large and small end wavy lines of the bevel gear preform surface;
FIG. 6 is a schematic surface view of a bevel gear preform;
FIG. 7 is a schematic illustration of a bevel gear preform according to the present invention;
FIG. 8 is a schematic illustration of a bevel gear preform according to the present invention.
Detailed Description
In order to make the technical means, the creation characteristics, the achievement purposes and the effects of the invention easy to understand, the invention is further described with the specific embodiments.
As shown in figure 1, the number of teeth z of the precision forging piece of the bevel gear is 30, and the modulus m of the large end of the precision forging piece ise2.5, a tooth width b of 15mm and a taper angle delta of 75. When the cylindrical blank is directly formed, the tooth form is difficult to fill, the product quality is influenced, in order to solve the technical problem,the precision plastic forming method of a bevel gear as described below is employed.
Blanking and blank pretreatment:
peeling the surface of the 20CrMnTi round bar stock into
Sawing and cutting a bar stock with the height of 15mm to obtain a cylindrical blank with the required specification, and then carrying out phosphorization, saponification, lubrication and softening annealing treatment as required to obtain the cylindrical blank.
Radial design of a preformed piece:
taking a section of the bevel gear precision forging piece shown in the figure 1 at a certain radial position, wherein the section comprises a cylindrical surface and a bevel gear part, measuring the sectional area of the cylindrical surface, as shown in the figure 2, measuring the sectional areas of a plurality of positions along the radial direction, if the sectional area is shown in the figure 3, converting the obtained sectional area into the height according to the cylindrical surface, connecting the height points of the radial positions, and correcting to obtain guide lines of the preformed piece corresponding to the bevel gear precision forging piece in the radial direction one by one, as shown in the figure 4.
Axial design of a preformed piece:
as shown in fig. 4, the corresponding wave-shaped radius r at the tooth-shaped big end of the bevel gear fine forging is respectively calculatedeThe corresponding wave height at the big end of the tooth shape is set as h e0, the corresponding wave height at the big end of the gear is hweTaking 0 to (ha + hf)/2, hweTaking 2, calculating the corresponding wave radius r at the small end of the tooth formiThe corresponding wave height h at the small end of the tooth formiThe corresponding wave height at the small end of the gear is hwiAnd taking 0.8, and making a large-end wavy line and a small-end wavy line by software according to the wavy line function, wherein the parameters of the wavy line in the example are shown in a figure 5.
Designing a preformed piece:
and as shown in fig. 6, taking the wavy lines at the large end and the small end as cross sections, taking the change curve of the sectional area along the radial direction as a guide line to sweep to obtain an upper surface pattern of the preformed piece, corresponding to each tooth of the bevel gear fine forging, and finishing the shape design of the preformed piece according to the upper surface pattern of the obtained preformed piece, as shown in fig. 7.
Preforming:
designing and manufacturing a pre-forging die according to the shape of the pre-formed piece
The cylindrical blank is placed into a pre-forging die corresponding to the pre-forming shape for closed die forging to obtain a pre-forming piece.
Finish forging: and placing the preformed piece into a finish forging die to carry out blocking upsetting extrusion forming on the tooth-shaped part, thereby obtaining the bevel gear finish forging piece with complete tooth shape.
And (3) after-forging treatment: and (3) cutting and polishing the metal burrs extruded from the clearance of the die during closed forging by using a grinding wheel according to requirements so as to improve the surface quality of the forging. And then carrying out heat treatment to improve the toughness of the bevel gear, and carrying out a small amount of grinding processing on the tooth-shaped part to further improve the tooth-shaped precision.
FIG. 8 shows the corresponding wavy wave height hw at the large end of the gear with 15 teeth zeTake 2, the corresponding wave height hw at the small endiTake 0, i.e. the preform with a rounded small end.
Therefore, according to parameters such as the tooth number, the modulus, the taper angle, the tooth width and the like of the bevel gear and the shape of a bearing tooth-shaped base body, the pre-forming shape of the bevel gear is designed quickly and efficiently, so that the flow of the bevel gear in the radial direction is reduced during finish forging forming, the difficulty of the flow in the axial direction is reduced, and the forming of a tooth-shaped part is ensured; the stress of the die is reduced, cracking is avoided, metal flow is reduced, die abrasion is reduced, and the method has important economic significance and technical value for application and popularization of the bevel gear precision plastic forming process.
The method is particularly suitable for straight bevel gears and can also be used for large-batch precision forming of helical bevel gears, spiral bevel gears, zero-degree bevel gears, cycloidal bevel gears and hypoid gears.
The pre-forming piece is similar to the shape of a finish forging piece, corresponds to a bevel gear part, is continuously changed along the section of a tooth form in the radial direction, and has periodic fluctuation around the axial direction, and meanwhile, the pre-forming piece is simple in shape and is easily obtained by pre-forging and forming a cylindrical blank.
The invention can also be used for the pre-forming design of the revolving body parts with the axial and radial regular characteristics.
The above description is only an example of the present invention and should not be taken as limiting the scope of the invention. The invention is not limited to the above examples, and various equivalent modifications and changes within the spirit of the invention, which are made by those skilled in the art, should be included within the scope of the invention as defined in the appended claims.
Claims (9)
1. A precision plastic forming method of a bevel gear is characterized in that: the method comprises the following steps:
obtaining the characteristic parameters of the bevel gear precision forging;
obtaining wave line data and a guide line through the characterization parameters;
manufacturing a pre-forging die according to the wavy line data and the guide line;
putting the cylindrical blank into the pre-forging die for closed die forging to obtain a preformed piece;
the wave line data comprise wave radii corresponding to a tooth-shaped large end of the bevel gear precision forging, wave heights corresponding to the tooth-shaped large end, wave heights corresponding to the gear large end, wave radii corresponding to a tooth-shaped small end, wave heights corresponding to the tooth-shaped small end and wave heights corresponding to the gear small end.
2. The precision plastic forming method of a bevel gear according to claim 1, characterized in that: the characterization parameters comprise tooth number, large end module, tooth width and taper angle.
3. The precision plastic forming method of a bevel gear according to claim 1, characterized in that: the corresponding wave-shaped radius at the big end of the tooth shape is obtained by the following formula: r ise＝(me×z+2×ha×cosδ)/2-Δ；
The corresponding wave at the big end of the tooth shapeThe shape height is set as he0; the corresponding wave height at the big end of the gear is 0 to (h)a+hf)/2；
The corresponding wave radius at the small end of the tooth shape is as follows:
ri＝re-b×sinδ；
the corresponding wave height at the small end of the tooth shape is set as follows:
hi＝he+b×cosδ
the corresponding wave height at the small end of the gear is as follows:
0～[ha-b×sin(δa-δ)+hf-b×sin(δ-δf)]/2；
wherein m iseLarge end modulus, z is the number of teeth of the bevel gear, haIs the tooth crest height, delta is the taper angle, deltaaAt tip angle, δfIs root angle, b is tooth width, hfThe tooth root is high, delta is a single-side gap for placing the preformed piece into a finish forging die, and the distance is 0.5-1 mm.
4. The precision plastic forming method of a bevel gear according to claim 1, characterized in that: the guide wire obtaining method includes:
calculating the cross-sectional areas of the bevel gear finish forging at a plurality of positions along the radial direction;
converting the area of the cross section into height according to the cylindrical surface, and connecting height points of all radial positions;
and correcting the height points to obtain guide lines of the preformed piece, which correspond to the bevel gear finish forgings in the radial direction one by one.
5. The precision plastic forming method of a bevel gear according to claim 4, characterized in that: the manufacturing method of the pre-forging die comprises the following steps:
acquiring a three-dimensional space coordinate value of a wave line;
in three-dimensional space, taking the large-end and small-end wave lines as cross sections, and scanning by a guide line to obtain an upper surface graph of the preformed piece;
preparing a pre-forging die according to the upper surface pattern of the pre-forming piece.
6. The precision plastic forming method of a bevel gear according to claim 5, characterized in that: the three-dimensional space coordinate value of the wavy line is calculated by the following formula:
Xt＝r×cosθ
Yt＝r×sinθ
Zt＝hw×sin(θ×z)+h
in the formula, Xt, Yt and Zt are coordinate values of X, Y and Z coordinate directions of a wave line in a three-dimensional space under given parameters respectively, r is a wave radius, hw is a wave height, theta is 0-360 degrees, Z is the number of bevel gear teeth, and h is the wave height.
7. The precision plastic forming method of a bevel gear according to claim 1, characterized in that:
the radial dimension of the preformed piece is 0.5-1 mm smaller than that of the bevel gear precision forging piece.
8. The precision plastic forming method of a bevel gear according to claim 1, characterized in that:
from the central shaft to the small tooth-shaped end, the cross-sectional area ratio of the cylindrical surfaces of the preformed piece and the bevel gear precision forging piece at any radial position is 1: 1;
from the small end of the tooth profile to the middle point of the tooth width, the ratio of the cross sections of the cylindrical surfaces of the preformed piece and the bevel gear precision forging piece at any radial position is (1-1.05): 1 is linearly changed to 1: 1;
from the middle point of the tooth width to the large end of the tooth shape, the ratio of the cross sections of the cylindrical surfaces of the preformed piece and the bevel gear precision forging piece at any radial position is 1: 1 is linearly changed to (1-1.05): 1.
9. the precision plastic forming method of a bevel gear according to claim 1, characterized in that: the method further comprises the following steps: and placing the preformed piece into a finish forging die to carry out blocking upsetting extrusion forming on the tooth-shaped part, thereby obtaining the bevel gear finish forging piece with the complete tooth shape.
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| CN114749597A (en) * | 2022-04-29 | 2022-07-15 | 力野精密工业（深圳）有限公司 | Precision forging process for novel compressor piston body of automobile |
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| MD3562F1 (en) * | 2006-04-04 | 2008-04-30 | Технический университет Молдовы | Process for bevel gear manufacturing |
| CN103056270B (en) * | 2013-01-08 | 2014-11-12 | 西北工业大学 | Method for designing gear forging die by three-order non-uniform rational B-splines |
| CN104728390B (en) * | 2015-02-06 | 2017-02-22 | 陕西理工学院 | Bevel gear tooth profile design method based on circular conical surface involute |
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