CN112247044B - Cold precision forming manufacturing process for bimetal gear - Google Patents
Cold precision forming manufacturing process for bimetal gear Download PDFInfo
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- CN112247044B CN112247044B CN202010954625.7A CN202010954625A CN112247044B CN 112247044 B CN112247044 B CN 112247044B CN 202010954625 A CN202010954625 A CN 202010954625A CN 112247044 B CN112247044 B CN 112247044B
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- aluminum alloy
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- steel ring
- alloy rod
- blank
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
- B21J5/002—Hybrid process, e.g. forging following casting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J3/00—Lubricating during forging or pressing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
- B21J5/02—Die forging; Trimming by making use of special dies ; Punching during forging
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
- B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
- B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
- B21J5/08—Upsetting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
- B21K1/00—Making machine elements
- B21K1/28—Making machine elements wheels; discs
- B21K1/30—Making machine elements wheels; discs with gear-teeth
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Forging (AREA)
Abstract
The invention provides a cold precision forming manufacturing process of a bimetallic gear, wherein the outer layer of the formed gear tooth shape is a steel material layer, so that the tooth shape part can be ensured to have better contact fatigue strength, an aluminum alloy material with lower density is used in the gear, the whole weight of the gear can be reduced, a complex space joint surface formed by metal flowing in the forging forming process is reserved on the joint surface of the steel material layer and the middle aluminum alloy material, and the joint strength between the steel material layer and the middle aluminum alloy material is effectively ensured. Meanwhile, the forming process is simple and easy to operate, the processes of the blank making process and the integral extrusion process are simple, the requirements of other auxiliary processes on equipment are lower, the integral production efficiency is higher, and the production cost is lower.
Description
Technical Field
The invention relates to the field of metal cold precision forging, in particular to a cold precision forming manufacturing process of a bimetallic gear.
Background
At present, the replacement of original part materials by lightweight materials is one of the main measures for lightweight design and manufacture, and the replacement of steel by lightweight materials can reduce the weight of vehicles, aerospace machinery and equipment machinery to a great extent. The aluminum alloy has the advantages of high specific strength, good plasticity and the like, and the density of the aluminum alloy is only about 30 percent of that of steel. At present, many vehicle body parts have replaced steel with aluminum alloys or other lightweight materials to reduce the weight of the vehicle body.
The gear is an important part in a mechanical device and one of basic core parts in a transmission machine. Gears are generally made of steel due to large bearing torque and load, and the weight of the gears and the gearbox is also large due to the large density of the steel. For gears with small bearing load, such as timing gears, aluminum alloy can be used for replacing steel to manufacture the gears, but considering that tooth surface failure is the main failure mode of the gears, the direct use of the aluminum alloy for replacing the steel to manufacture the gears cannot meet the contact fatigue strength of the gears. In order to achieve the purpose of reducing the weight of the gear and simultaneously reducing the strength of the gear less, two metals are used for manufacturing the gear, steel materials are used for gear teeth participating in meshing, aluminum alloy materials are used for parts inside the gear teeth, a bimetal gear is manufactured, and meanwhile the requirements of the weight reduction and the strength of the gear are met.
Disclosure of Invention
The invention aims to provide a cold precision plastic forming process of a bimetallic gear, which can realize the aim of designing and manufacturing the gear in a light weight manner.
In order to achieve the purpose, the invention adopts the technical scheme that: a cold precision forming manufacturing process of a bimetal gear comprises the following steps:
step one, blanking: preparing a steel ring and an aluminum alloy rod which are matched, wherein the height of the aluminum alloy rod is higher than that of the steel ring;
step two, annealing: annealing and roll finishing the steel ring and the aluminum alloy rod according to respective material properties, and cleaning the inner surface of the steel ring and the outer circumferential surface of the aluminum alloy rod;
step three, compounding and blank making: inserting an aluminum alloy rod into the inner side of the steel ring, putting the aluminum alloy rod into a blank-making female die together, performing bidirectional extrusion through a blank-making upper punch and a blank-making lower punch, upsetting the aluminum alloy rod with the size higher than that of the steel ring, and enabling the inner surface of the steel ring to be in close contact with the outer circumferential surface of the aluminum alloy rod to form an intermediate blank;
step four, lubricating: lubricating the intermediate blank;
step five, extrusion molding: and (2) putting the lubricated intermediate blank into a tooth-shaped female die for gear forming, and then bidirectionally filling the intermediate blank into the tooth-shaped part of the tooth-shaped female die through bidirectional extrusion of a gear forming upper punch and a gear forming lower punch to form the bimetal tooth-shaped gear, wherein the joint surface of the inner surface of the steel ring and the outer circumferential surface of the aluminum alloy rod after forming is a tooth-shaped surface and is in drum-shaped distribution as a whole.
Furthermore, after the upsetting of the aluminum alloy rod is completed, the aluminum alloy rod is flush with the end face of the steel ring.
Further, the thickness of the steel ring is 70% -80% of the height of the bimetal tooth-shaped gear teeth.
Furthermore, the outer diameter of the steel ring is 0.4-0.6mm smaller than the root circle of the bimetallic tooth-shaped gear, and the inner diameter of the steel ring is 0.3-0.5mm larger than the outer diameter of the aluminum alloy rod.
Furthermore, a stepped hole for placing the aluminum alloy rod and the steel ring is formed in the blank making female die, the aperture of the upper part of the stepped hole is 0.2-0.3mm larger than the outer diameter of the steel ring, and the aperture of the lower part of the stepped hole is 0.5-0.8mm larger than the inner diameter of the steel ring.
Furthermore, the stepped hole is in clearance fit with the blank making upper punch and the blank making lower punch.
Compared with the prior art, the invention has the beneficial effects that:
1. the core material of the bimetal gear formed by the process is changed into the aluminum alloy material with lower density, so that the overall weight of the bimetal gear is reduced by about 50 percent compared with that of a steel gear, and the lightweight manufacturing of the gear is realized; the gear teeth which participate in meshing can meet the contact fatigue strength of the gear by using steel, and the strength of the tooth surface can be effectively improved due to the work hardening generated by plastic deformation;
2. the tooth-shaped steel part of the bimetallic gear formed by the process is tightly combined with the core aluminum alloy part, the combined surface is a tooth-shaped surface and is distributed like a drum on the whole, and the combined surface is a complex space curved surface which is automatically generated by the flow of blank metal in a female die, so that the two metals can be effectively prevented from being peeled off when the gear is subjected to a certain tangential force and an axial force;
3. the forming process is simple and easy to operate, the procedures of the blank making process and the integral extrusion process are simple, the requirements of other auxiliary procedures on equipment are lower, and the integral production efficiency and the integral production cost are lower.
Drawings
FIG. 1 is a schematic structural view of a bimetallic tooth gear prepared by the process of the present invention;
FIG. 2 is a process diagram of the precision forming process of the present invention;
FIG. 3 is a schematic structural view of the formed steel ring;
FIG. 4 is a schematic structural view of a formed aluminum alloy rod;
FIG. 5 is a schematic view of extrusion forming after a steel ring and an aluminum alloy rod are placed into a blank-making female die;
FIG. 6 is a schematic view showing a state where an intermediate material is placed in a tooth-shaped female die for molding;
the labels in the figure are: 1. the method comprises the following steps of (1) a steel ring, 100 parts of the inner surface of the steel ring, 2 parts of an aluminum alloy rod, 200 parts of the outer circumferential surface of the aluminum alloy rod, 3 parts of a blank making upper punch, 4 parts of a blank making female die, 5 parts of a blank making lower punch, 6 parts of a gear forming upper punch, 7 parts of a tooth-shaped female die, 8 parts of a gear forming lower punch.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be described clearly and completely with reference to the accompanying drawings in the present invention, and it is obvious that the described embodiments are some embodiments of the present invention, but not all embodiments, and all other embodiments obtained by a person of ordinary skill in the art based on the embodiments of the present invention without creative efforts belong to the protection scope of the present invention.
As shown in fig. 1 and 2, the cold precision forming process of the bimetal gear comprises the following steps: (1) blanking: the steel ring 1 is prepared by sawing a pipe material, the aluminum alloy rod 2 is prepared by sawing an aluminum alloy rod material, and the aluminum alloy rod is higher than the steel ring by a certain height; (2) annealing: annealing and roll finishing are carried out on the steel ring 1 and the aluminum alloy rod 2 according to respective material properties, and cleaning treatment is carried out on the inner surface of the steel ring 1 and the outer circumferential surface of the aluminum alloy rod 2; (3) and (3) steel ring and aluminum alloy bar composite blank making: inserting an aluminum alloy rod 2 into the inner side of a steel ring 1, putting the aluminum alloy rod and the steel ring together into a blank-making female die 4, performing bidirectional extrusion through a blank-making upper punch 3 and a blank-making lower punch 5, upsetting the aluminum alloy rod 2 with the size and height higher than that of the steel ring, completely filling the aluminum alloy rod 2 into the steel ring 1, enabling the inner surface of the steel ring 1 to be in close contact with the outer circumferential surface of the aluminum alloy rod 2, forming an intermediate blank, and selecting a smaller extrusion force F1 during upsetting; (4) lubrication: lubricating the intermediate blank; (5) and (3) gear extrusion molding: the lubricated intermediate blank is placed into a gear female die 7 for gear forming, and the gear forming upper punch 6 and the gear forming lower punch 8 are used for bidirectional extrusion, so that the intermediate blank is bidirectionally filled in the tooth-shaped part of the tooth-shaped female die 7 to form the bimetal tooth-shaped gear, the forming force F2 of the bimetal tooth-shaped gear is about 23% smaller than that of the common extrusion of a steel solid blank, as shown in figures 3 and 4, the inner surface 100 of a formed steel ring and the outer circumferential surface 200 of an aluminum alloy rod, namely the bonding surface of two metals, is a similar tooth-shaped surface and is in drum-shaped distribution as a whole, the bonding surface is a complex space curved surface which is automatically generated by the blank metal flowing in the female die, and the two metals can be effectively prevented from being peeled off when the gear is subjected to certain tangential force and axial force.
In the embodiment, the thickness of the steel ring is about 75% of the height of the manufactured double-metal toothed gear, the outer diameter of the sawed steel ring 1 is 0.4-0.6mm smaller than the root circle of the double-metal toothed gear, the inner diameter of the steel ring 1 is 0.3-0.5mm larger than the outer diameter of the aluminum alloy bar 2, the height of the aluminum alloy bar above the height of the steel ring can ensure that the inner hole of the steel ring is filled with aluminum alloy after the end faces of the two are upset, and the size can be calculated through volume.
As shown in figure 5, the inner hole of the blanking female die 4 is a stepped hole with a circular platform, the aperture of the upper part of the stepped hole is 0.2-0.3mm larger than the outer diameter of the steel ring blank, the aperture of the lower part of the stepped hole is 0.5-0.8mm larger than the inner aperture of the steel ring blank, and the upper blanking punch 3, the lower blanking punch 5 and the stepped hole arranged in the blanking female die 4 are in clearance fit, and the fit clearance is 0.4-0.6 mm.
As shown in fig. 6, the gear extrusion forming process in the forming process of the present invention comprises: the gear forming upper punch 6 and the gear forming lower punch 8 bidirectionally extrude the intermediate blank, the aluminum alloy and the steel metal in the intermediate blank fill the gear according to the flow rule, and the two formed metal junction surfaces are tooth-like surfaces and are distributed in a drum shape on the whole. The contact surface is changed from the original cylindrical surface to a space curved surface, the surface area is increased, the combination of the steel metal and the aluminum alloy metal of the newly generated contact surface is tighter, and impurities and metal oxides do not exist between the steel metal and the aluminum alloy metal.
The outer layer of the formed gear tooth shape is a steel material layer, so that the tooth shape part can be ensured to have better contact fatigue strength, an aluminum alloy material with lower density is used in the gear, the whole weight of the gear can be reduced, a complex space joint surface formed by metal flowing in the forging forming process is reserved on the joint surface of the steel material layer and the middle aluminum alloy material, and the joint strength between the steel material layer and the middle aluminum alloy material is effectively ensured. Meanwhile, the forming process is simple and easy to operate, the processes of the blank making process and the integral extrusion process are simple, the requirements of other auxiliary processes on equipment are lower, the integral production efficiency is higher, and the production cost is lower.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims (6)
1. A cold precision forming manufacturing process of a bimetal gear is characterized by comprising the following steps:
step one, blanking: preparing a steel ring and an aluminum alloy rod which are matched, wherein the height of the aluminum alloy rod is higher than that of the steel ring;
step two, annealing: annealing and roll finishing the steel ring and the aluminum alloy rod according to respective material properties, and cleaning the inner surface of the steel ring and the outer circumferential surface of the aluminum alloy rod;
step three, compounding and blank making: inserting an aluminum alloy rod into the inner side of the steel ring, putting the aluminum alloy rod into a blank-making female die together, performing bidirectional extrusion through a blank-making upper punch and a blank-making lower punch, upsetting the aluminum alloy rod with the size higher than that of the steel ring, and enabling the inner surface of the steel ring to be in close contact with the outer circumferential surface of the aluminum alloy rod to form an intermediate blank;
step four, lubricating: lubricating the intermediate blank;
step five, extrusion molding: the lubricated intermediate blank is placed into a tooth-shaped female die for gear forming, then the tooth-shaped part of the tooth-shaped female die is bidirectionally filled with the intermediate blank through the bidirectional extrusion of a gear forming upper punch and a gear forming lower punch to form the bimetal tooth-shaped gear, and the junction surface of the inner surface of the steel ring and the outer circumferential surface of the aluminum alloy rod after forming is a complex space curved surface which is automatically generated by the flow of the intermediate blank in the female die, specifically a tooth-shaped surface and is in drum-shaped distribution as a whole.
2. The cold precision forming manufacturing process of the bimetal gear according to claim 1, wherein after the upsetting of the aluminum alloy rod is completed, the aluminum alloy rod and the end face of the steel ring are flush.
3. The cold precision forming manufacturing process of the bimetallic gear as in claim 2, wherein the thickness of the steel ring is 70% -80% of the height of the bimetallic toothed gear.
4. The cold precision forming process of bimetallic gears according to claim 3, characterized in that the outer diameter of the steel ring is 0.4-0.6mm smaller than the root circle of the bimetallic tooth-shaped gear, and the inner diameter of the steel ring is 0.3-0.5mm larger than the outer diameter of the aluminum alloy rod.
5. The cold precision forming manufacturing process of the bimetal gear according to claim 1, characterized in that a stepped hole for placing the aluminum alloy rod and the steel ring is formed in the blank-making female die, the upper hole diameter of the stepped hole is 0.2-0.3mm larger than the outer diameter of the steel ring, and the lower hole diameter of the stepped hole is 0.5-0.8mm larger than the inner diameter of the steel ring.
6. The cold precision forming process of bimetallic gears as in claim 5, wherein the stepped bore is in clearance fit with both the upper and lower blank punches.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202010954625.7A CN112247044B (en) | 2020-09-11 | 2020-09-11 | Cold precision forming manufacturing process for bimetal gear |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202010954625.7A CN112247044B (en) | 2020-09-11 | 2020-09-11 | Cold precision forming manufacturing process for bimetal gear |
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| CN112247044A CN112247044A (en) | 2021-01-22 |
| CN112247044B true CN112247044B (en) | 2022-07-01 |
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| US11646633B2 (en) | 2021-04-06 | 2023-05-09 | Hamilton Sundstrand Corporation | Aircraft electric motor |
| CN113478188B (en) * | 2021-07-28 | 2022-07-29 | 重庆创精温锻成型有限公司 | Parking gear tooth profile lateral extrusion forming method |
| CN113798430B (en) * | 2021-08-11 | 2024-06-14 | 广东华昌集团有限公司 | Preparation method of steel-aluminum conductor rail based on coextrusion and conductor rail |
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| DE19905953A1 (en) * | 1998-02-13 | 1999-12-30 | Haferkamp Heinrich Dietrich | Production of metal gearwheel with layered material structure, and resultant gearwheel |
| JP4476051B2 (en) * | 2004-07-01 | 2010-06-09 | 株式会社ハーモニック・ドライブ・システムズ | Method for manufacturing rigid internal gear of wave gear device |
| DE102008019041B4 (en) * | 2007-04-18 | 2019-06-06 | Neumayer Tekfor Engineering Gmbh | gear |
| CN102489978A (en) * | 2011-12-04 | 2012-06-13 | 北京机电研究所 | Hot and cold composite precision forging forming method of great-modulus high-thickness straight-tooth cylindrical gear |
| DE102012017040A1 (en) * | 2012-08-29 | 2014-03-27 | Gkn Sinter Metals Holding Gmbh | Method for producing a composite component and a composite component |
| JP6090436B2 (en) * | 2013-04-22 | 2017-03-08 | 日本精工株式会社 | Method of manufacturing race ring member and metal material for race ring member |
| CN104057201B (en) * | 2014-06-27 | 2016-04-27 | 中航力源液压股份有限公司 | The two alloy structure diffusion welding method of plunger hydraulic pump motor rotor |
| DE102017104159B4 (en) * | 2017-02-28 | 2021-01-21 | Bayerische Motoren Werke Aktiengesellschaft | Gear for a balance shaft and a balance shaft |
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