201117895 六、發明說明： 【發明所屬之技術領域】 本發明係有關於-種直傘齒輪锻造成形方法及其使用之 模具，尤指-觀大料_流難Μ轉力㈣锻模 承受，以減少鍛材在終鍛成型的流動量，俾能大幅降低摩擦 對終鍛模具齒部所造成磨損者。 ① 【先前技術】 由於直傘齒輪鍛造過程中對於精度要求最重要的部分在 於齒廓，但為成型齒廓部分也相對應造成了大量磨耗，、&刀_ 批鍛件的齒廓差異性較大。按，㈣輪是傳遞相絲 傳動的主要零件’在傳遞交轴傳動的零件中它能以較⑽效 率、更平穩地傳遞轉矩。它不但能傳遞叫線相交成直角的轉 動，也能傳遞兩軸線相交成鈍角或銳角的轉動。 直傘齒輪的齒廓加工方法很多’而目前大多還是以切削法 為主，一般工業上傘齒輪的切削加工方法有三大類：（1)滾切 法（generate)。（2)成形法（format)。（3)仿形法。直傘齒輪製 程上的主要製造程序為原料今鍛胚^粗切削今熱處理今精 切削+研磨，其程序複雜且費時，在切削時須以一齒一齒往 複式銑削，齒數越多越費時，而鍛造是以高壓一次成形，在時 間上就相當節省；在材料的強度上，鍛造品在抗彎強度和衝擊 強度的實驗證明下都比切削品高，如以精密鍛造齒輪的技術來 製成，可在製程上大量的節省成本及時間’提升產業的競爭力。 201117895 ' 在國内外也相當多學者與業界開始注重齒輪鍛造的發 •明’因其在材料利用性、生產效率與產品強度上有其優勢在， 但在模具的壽命與產品精度的要求上，對模具設計有著相當大 的困難。在先前發明裡’ CHOI [1]提出以洩壓口應用於齒輪鍛 造模具設計’在不影響到齒廓的填充下達到降低成形負荷之優 勢。LEE[2]提出以有限元素法模擬傘齒輪鍛造成形過程，並利 碣模具與沖碩設計來針對成形過程的填充不足做改善。S0NG[3] I讨論胚料的外徑大小與擺放位置對成形效果之影響，並解決成 衫不均與成形缺陷等問題。Sayed Aziz[4]在圓柱齒輪的預成 炎鍛L裡，已將漸開面以直邊代替來達到降低成形摩擦效果。 艰清萍[5-6]利用分流法在上下模設計一小凸出塊以控制材料 旅動。 一般直傘齒輪鍛造鍛造流程如圖一所示，從鍛材（l〇〇a)裁 剪須經過一次預成形為預成型鍛件（l〇〇b)，最後才進行齒形成 裂部为以成為直傘齒輪（l〇〇c)成品，而預成型锻件（l〇〇b)係以 • I：傘齒輪（100c)的齒根做為預成梨模具幾何設計基準。該習用 鱗構的優勢在於預成型後的鍛件容易放於終鍛模具内，因而容 易對準中心；惟，在終鍛模具的齒部磨耗對鍛件的精度影響卻 仍然無法減少。上述之傘齒輪鍛造問題大多以成形負荷、模具 應力與材料填充性問題做討論’很少針對預成型設計做創新性 的開發’以在預成形模具疋單純的以傘齒輪外形做為齒胚幾何 來開發，在終锻模具再來進行遗廓的填充（如美國發明專利 201117895 .US7, 191，521及US5, 946, 963號所示之結構），以致材料在往模 -具齒部填充的同時將產生極大的摩擦力’這不官是在冷鍛或熱 鍛來說’終鍛模具的齒部磨耗會相當的大，將造成同一批量生 產的直傘齒輪精度變動範圍加大。有鑑於此，本發明將針對直 傘齒輪預成形模具進行創新設計與開發，以減少材料在終鍛成 形時的流動量。 再者’由於漸開面齒輪之嚙合角恒定不變的緣故，而且在 馨數值上恒等於節圓壓力角，在齒輪傳動中，兩齒磨間正壓力的 方向是沿其接觸點的公法線，該方向隨喃合角的改變而變化。 故齒廊間正壓力的方向亦始終不變，故可提升於齒輪傳動的平 穩性，以致現今的齒輪的齒廓設計大多以漸開面齒輪為主流。 參考文獻 [1] . J. C. Choi, Y. Choi, “Precision forging of spur gears with inside relief" International Journal of Machine Tools & Manufacture 39 (1999) 赢 1575-1588 。 [2] . Y. K. Lee, S. R. Lee, C. H. Lee, D. Y. Yang, “Process modification of bevel gear forging using three-dimensional finite element analysis” Journal of Materials Processing Technology 113 (2001) 59-63。 [3] . J. -H. Song, Y.-T. Im， “Process design for close-die forging of bevel gear by finite element analysis” Journal of Materials Processing Technology 192-193(2007)1-7 。 [4] . El-Sayed Aziz, C. Chassapis, “Development of process 201117895 • optimization for an intelligent knowledge-based system for spur gear -precision forging die design” ASME 2004 Design Engineering Technical Conferences and Computers and Information in Engineering Conference,201117895 VI. Description of the invention: [Technical field to which the invention pertains] The present invention relates to a method for forging a straight bevel gear and a mold for use thereof, and more particularly to a large-material _ flow difficult force (four) forging die, Reducing the flow of forgings in the final forging, 俾 can greatly reduce the friction caused by the wear of the final forging die teeth. 1 [Prior Art] Since the most important part of the precision requirements for straight bevel gear forging is the tooth profile, the corresponding profile of the profiled tooth profile also causes a large amount of wear, and the tooth profile difference of the & Big. Press, (four) wheel is the main part of the transmission of the phase wire transmission. In the part that transmits the cross shaft transmission, it can transmit the torque more smoothly and more smoothly. It not only transmits the rotation of the line intersecting at right angles, but also transmits the rotation of the two axes at an obtuse or acute angle. There are many methods for machining the profile of straight bevel gears. At present, most of them are based on cutting methods. There are three main types of machining methods for bevel gears in general industry: (1) Rolling method. (2) Forming method. (3) Profiling method. The main manufacturing procedure on the straight bevel gear process is the raw material, the forging embryo, the rough cutting, the heat treatment, the fine cutting and the grinding. The procedure is complicated and time-consuming. It must be reciprocally milled with one tooth and one tooth during cutting. The more the number of teeth, the more time-consuming. Forging is a high-pressure one-time forming, which is quite economical in terms of time; in terms of the strength of the material, the forged product is higher than the cutting product in the experimental proof of the bending strength and the impact strength, such as the technology of precision forging gears. It can save a lot of cost and time in the process to 'improve the competitiveness of the industry. 201117895 ' At home and abroad, quite a few scholars and the industry have begun to pay attention to the gear forging. Because of its advantages in material utilization, production efficiency and product strength, but in the life of the mold and product accuracy requirements, There are considerable difficulties in mold design. In the prior invention, 'CHOI [1] proposed the application of a pressure relief port to a gear forging die design to achieve the advantage of reducing the forming load without affecting the filling of the tooth profile. LEE [2] proposed to simulate the bevel gear forging process by the finite element method, and to improve the filling process of the forming process by using the mold and the punching design. S0NG[3] I discusses the influence of the outer diameter size and placement position of the blank on the forming effect, and solves problems such as unevenness of the shirt and forming defects. In the pre-invented forging L of the spur gear, Sayed Aziz [4] has replaced the involute surface with a straight edge to reduce the forming friction effect. Ji Qingping [5-6] used the split method to design a small protruding block in the upper and lower molds to control the material travel. Generally, the forging process of straight bevel gears is as shown in Fig. 1. The cutting from the forged material (l〇〇a) must be pre-formed into a preformed forging (l〇〇b), and finally the teeth are formed into cracks to become straight. The bevel gear (l〇〇c) is finished, and the preformed forging (l〇〇b) is based on the tooth root of the bevel gear (100c) as the pre-formed pear mold geometric design basis. The advantage of this conventional squama is that the preformed forgings are easily placed in the final forging dies, so that they are easily aligned with the center; however, the accuracy of the tooth wear of the final forging dies on the forgings cannot be reduced. The above-mentioned bevel gear forging problems are mostly discussed in terms of forming load, mold stress and material filling problem. "There is rarely an innovative development for preform design". In the preforming mold, the simple bevel gear shape is used as the tooth embryo geometry. To develop, in the final forging die, to carry out the filling of the outline (such as the structure shown in the US Patent No. 201117895. US 7,191,521 and US Pat. No. 5,946,963), so that the material is filled in the mold-toothed portion. At the same time, it will produce great friction. This is not the case. In cold forging or hot forging, the tooth wear of the final forging die will be quite large, which will increase the range of precision of the straight bevel gear of the same batch production. In view of this, the present invention will be innovatively designed and developed for straight bevel gear preforming dies to reduce the amount of material flowing during final forging. Furthermore, 'because the meshing angle of the involute gear is constant, and the enthalpy value is always equal to the pitch angle, in the gear transmission, the direction of the positive pressure between the two teeth is the common normal along the contact point. This direction changes as the angle of the coma changes. Therefore, the direction of the positive pressure between the tooth spaces is always constant, so that the stability of the gear transmission can be improved, so that the gear profile design of today's gears mostly adopts the gradually opening gear as the mainstream. References [1] . JC Choi, Y. Choi, “Precision forging of spur gears with inside relief" International Journal of Machine Tools & Manufacture 39 (1999) Win 1575-1588. [2] . YK Lee, SR Lee, CH Lee, DY Yang, "Process modification of bevel gear forging using three-dimensional finite element analysis" Journal of Materials Processing Technology 113 (2001) 59-63. [3] . J. -H. Song, Y.-T. Im, "Process design for close-die forging of bevel gear by finite element analysis" Journal of Materials Processing Technology 192-193 (2007) 1-7. [4] . El-Sayed Aziz, C. Chassapis, "Development of process 201117895 • optimization for an intelligent knowledge-based system for spur gear -precision forging die design” ASME 2004 Design Engineering Technical Conferences and Computers and Information in Engineering Conference,
September 28_0ctober 2, 2004，Salt Lake City, Utah, USA。 [5] . 張清萍’“齒輪精鍛過程三維數值模擬及關鍵工藝技術發明”山東大 學博士學位論文，2004。 [6] .張清萍、趙國群、奕貽國，“直齒圓柱齒輪精锻成型工藝改進及模擬 鲁分析”，鍛壓技術2004年第4期，pp. 11-13。 【發明内容】 本發明之主要目的在提供一種直傘齒輪鍛造成形方法及 其使用之模具，主要係使大部分鍛材流動產生的摩擦力由預鍛 模具來承受，以減少鍛材在終鍛成型的流動量，而可大幅降低 摩擦力對終鍛模具所造成磨損，因而可以大幅提升直傘齒輪之 齒廓成型的精度、減少鍛造批量整體精度的差異性及產品的競 _爭力佳，進而得以延長模具的使用壽命等諸多特點。 為達上述功效本發明採用之技術手段係將預鍛模具内形 成預成型模穴，並於終鍛模具内形成終成型模穴，終成型模穴 具有複數個與直傘齒輪之每一齒部相對應的第二齒腔，第二齒 腔包含二個為弧形面的第二漸開面齒廊，將锻材予以裁剪為成 型所需之預定雜並置人預鍛模具㈣行锻打而形成預成型 鍛件，再將預成型鍛件置入終锻模具内進行锻打，使預成型鍛 件脹滿終锻模具之整附終成型模穴而成型為具有漸開面齒廊 201117895 •的直傘齒輪成品’其中，預成型模穴具有複數個與直傘齒輪之 •每一齒部相對應第一齒腔，且第一齒腔包含有二個為平面的第 一漸開面齒廓，藉以減少鍛材在終鍛成型的流動量’俾能大幅 降低摩擦力對終鍛模具所造成磨損者。 【實施方式】 壹•本發明的基本特徵 1.1直傘齒輪鍛造成型方法 # 請參看圖二、七及圖八所示’本發明主要係於預鍛成型時 先鍛出具有部分齒廓11的預成型鍛件l〇b，以減少終锻模具 22終成型模穴220部分之磨耗。為達成上述功效，本發明鍛造 成型方法係包括以下步驟： (a) 準備有一預鍛模具21及一終鍛模具22,如圖五及圖六 所示，該預鍛模具21内形成一預成型模穴210;如圖七及圖八 所示，該終鍛模具22内形成一終成型模穴220，該終成型模穴 _ 220具有複數個第二齒腔222，每一該第二齒腔222與該直傘 齒輪之每一齒部相對應，該第二齒腔222與該齒部的整個齒廓 相符合，該第二齒腔222包含有二個第二漸開面齒廓221，該 第二漸開面齒廓221為一弧形面； (b) 將一鍛材10a予以裁剪為成型所需之預定形狀。 (c) 將該鍛材10a置入該預鍛模具21内進行鍛打而形成一 預成型鍛件101^ (d) 將該頓成型鍛件10b置入該終鍛模具22之終成型模穴 ί 7 201117895 220内進行鍛打，使該預成型鍛件1〇b脹滿該終鍛模具22之整 附該終成型模穴220而成型為具有漸開面齒廓的該直傘齒輪成 品。 其中，如圖五、六所示，本發明之方法的主要特徵在於， 該預鍛模具21之該預成型模穴210具有複數個第一齒腔213, 每一該第一齒腔213與該直傘齒輪之每一齒部相對應，該第一 齒腔213與該齒部的局部齒廓相符合，該第一齒腔213包含有 一個第一漸開面齒廓211，而且該第一漸開面齒廓211為平 面，使該鍛材l〇a於預鍛模具21内進行鍛打後，使該緞材預 先被分割材料，並使該預成型鍛件1〇b具有該直傘齒輪之局部 齒廓。 如圖五、六所示，本發明之直傘齒輪鍛造成形方法中的一 種具體貫施例，該第一齒腔213的二個第一漸開面齒廓211以 一第一弧面212連接。 本發明之直傘齒輪鍛造成形方法中的一種具體實施例，如 圖五、六所示，預鍛模具21之第一齒腔213的二個第一漸開 面齒廓211以一第一弧面212連接。如圖七、八所示，終鍛模 具22之第二齒腔222的二個第二漸開面齒廓221以一第二弧 面223連接，比較圖九、十所示，該第一弧面212與該第二弧 面223形狀相同。 如圖五、六所示，本發明之直傘齒輪鍛造成形方法中的一 201117895 種具體實施例，該預鍛模具21包括有一供該鍛材l〇a置入的 第一下模214 ’及一用以衝擊該锻材i〇a並與該第一下模214 模合的衝頭215 ’該預成型模穴21〇設於該第一下模214上。 如圖七、八所示，本發明之直傘齒輪鍛造成形方法中的一 種具體實施例’該終鍛模具22包括有一供該預成型鍛件i〇b 置入的第二下模224 ’及一用以衝擊該預成型鍛件i〇b並與該 第二下模224模合的衝頭225，該終成型模穴22〇設於該第二 鲁下模224上。 明參看圖一、二、五及圖六所示，本發明之預鍛成型步驟， 將鍛材l〇a置入預鍛模具21内進行鍛打，使鍛材1〇a預先分 割材料以被鍛成一預成型鍛件1〇b，該預成型鍛件1〇b具有一 直傘齒輪10c之局部齒廓η，如圖二、三所示。 請參看圖二、四、七及圖八所示’本發明之終鍛成型步驟， 鲁係將預成型鍛件l〇b置入一終鍛模具22内進行鍛打，使預成 型鍛件10b脹滿終鍛模具22之整附終成型模穴22〇，進而成型 為具有漸開面齒廓12的直傘齒輪1〇c成品。 1· 2直傘齒輪鍛造成形模具 請參看圖二、五及圖七所示’本發明直傘齒輪锻造成形模 具主要係用來產製磨耗較少且精度較佳的直伞齒輪，為達上述 功效，直傘齒輪锻造成形模具則包括一預鍛模具Μ及一終鍛 模具22。 、 201117895 如圖五及圖六所示’該預鍛模且 210,鍛材10a置入該預锻模具21之内形成一預成型模穴 打而形成-預成型鍛件i〇b。如圖七^顯穴210内進行鍛 00 及圖八所示，該終鍛模且 220 ^ 220 ^ 第二齒腔222與該直傘齒輪之每-齒部相 十應，δ亥第一齒腔222與該齒部的整 ^ Οοο ^ ^ ι個齒廓相符合，該第二齒 腔222包含有二個第二漸開面齒廓 圈哪以1’該第二漸開面齒廓221 芍一弧形面。再將預成型鍛件1()b 卞iUb置入該終鍛模具22之終成 9〇 預成•鍛件l〇b脹滿該終鍛模具 〇之整附該終成型模穴220而成刑盍1女& 叩战虫為具有漸開面齒廓12的該 直傘齒輪成品。 其中纟圖五及圖八所不’本發明之模具的主要特徵在 於，該預祕具21之該職型模穴21()具有複數個第一齒腔 13 ’每-該帛齒腔213與該直傘齒輪之每—齒部相對應， 忒第一齒腔213與該齒部的局部齒廓相符合，該第一齒腔213 包合有二個第-漸開面齒廓21卜而且該第—漸開面齒廓211 為平面，使該鍛材l〇a於預鍛模具21内進行鍛打後，使該緞 材10a預先被分割材料，並使該預成型緞件1〇b具有該直傘齒 輪之局部齒廓。 貳·本發明較佳實施例的運作 請參看附件二圖片a〜e所示，首先設定直傘齒輪齒廓設計 參數與模擬參數，如附件一之表一及表二所示，本發明係取用 201117895 J UI輪齒i來進行’有此設計參數後，便能依據本發明發展的 直傘齒輪A4軟體獲彳讀輪幾何，在配合本發明的預鍛齒廓設 汁卩可加决產cm研發時程。本發明的預鍛模具齒麼乃是將終 鍛齒廓的漸開面用-平㈣齒廓斜面來減，使預鍛成形步驟 +即預先^以分赌料，吸收锻造過程大部份的成形摩擦，減 少終鍛模具_耗，增料锻模具的使用壽命。附件二圖片a〜c 所示為本發明之預成型鍛件的部分齒廓，用以比較傳統成形過 程與本發明研發預鍛模具的成形過程，如附件二圖片d、e所 示。 由成形過程得知，本發明之預鍛模具在預鍛成形步驟中已 將材料分割完畢，故而在終锻成形步驟時，使終鍛模具僅以脹 滿漸開面齒廓為目的，以達到降低傳統鍛造的摩擦與成形過 程。反觀傳統鍛造成形過程中，在預成型時尚未分割材料與填 充齒廓，所以在置換終鍛模具後成形過程，是為分割材料與鼓 脹成形同步，終鍛模具的磨耗較為嚴重。本發明則是將分割材 料由預鍛模具成形來達成’終鍛模具成形則以脹滿齒部為主要 目的，以減少成型摩擦來降低對終鍛模具造成的磨耗’從而減 少整批鍛造齒輪的精度盖異性。為減少傳統直傘齒輪鍛造過程 中，對模具齒部的磨耗’本發明在預鍛模具齒形模穴部分係以 平面來取代直傘齒輪產品的漸開面部分。由模擬結果得知’預 锻模旦由斜切平面的逾腐设计下’能有效的分割材料減少終鍛 1 11 201117895 '的成形摩擦，在終鍛成形步驟時，材料是以鼓脹方式充滿整附 •終成型模穴，所以不會影響所需的產品成型結果。 參·有限元素模擬分析 有限元素法的基本概念是將原本連續的定義域加以離散 化，然後通過力的平衡條件，建立一套線性方程組，並將此離 散化後之勁度矩陣（Stiffness Matrix)以數值方法解出，便可 得到各單元和節點的位移、應力。其實就是用較簡單的問題代 替複雜問題後再求解。此方法可採用不同的材料模式，例如剛 塑性模式、彈塑性模式、彈-黏塑性模式等。將各個元素的構 成方程式導出後，再導入邊界條件後求出代數方程式。目前， 有限元素法已成為金屬塑性成形模擬的主要方法。 剛塑性邊界值問題可描述如下：設一剛塑性體，體積為V， 表面積為，，在作用力6之下整個變形體處於塑性狀態，表面s分 為\和〜兩部分，其中\上給定作用力S\上給定速度v,°。 它由以下塑性方程與邊界條件定義，即： (1) 平衡微分方程 °V"=0 (2-1) (2) 幾何方程(速度一應變速率關係方程） ευ = 2^+ν^ (2-2) (3) 本構方程(應力應變關係方程） 12 201117895 3# ~ϊ§ σϋ ε... 式中、σ和崎縣較應力和等效紐率表示為 (2-4) (2-3) ⑷7鋼材滿足VCinMlses降伏準則，採用直角座標系之等效應 力f及等效應變率#可定義如下： h#M+(K+(n)2+6(r 二办 (2-5) t 丁队畎 «)]+ (2_6) 塑流應力關義HQllQmon-Ludwik之轉法則，即 σ = Κεη (2-7) 根據Levy-Mises流動法則的全應變理論，可得應力與應 變有下列關係式 ^ =[^x~am]：[ay-am]：[az-aj 1 (2-8) 其中 σ<Β=?(σ:+σ，+<τ》 (5) SI彈性應變不計，由體積保持—^，在各點處，須滿 足下式 ' εχ + ε> + εζ = 〇 (2-10) (6)邊界條件，包括力邊界條件和速度邊界條件，分別為. m (2-11) .September 28_0ctober 2, 2004, Salt Lake City, Utah, USA. [5] . Zhang Qingping's “Three-dimensional numerical simulation of gear precision forging process and invention of key process technologies”, Ph.D. Thesis of Shandong University, 2004. [6]. Zhang Qingping, Zhao Guoqun, and Shu Guo, “Innovation and Simulation of Precision Forging Process of Spur Gears”, Forging Technology, No. 4, 2004, pp. 11-13. SUMMARY OF THE INVENTION The main object of the present invention is to provide a straight bevel gear forging method and a mold for use thereof, which mainly reduces the friction generated by the flow of most forging materials by the pre-forging die to reduce the forging in the final forging. The amount of flow formed can greatly reduce the friction caused by the friction on the final forging die, so that the accuracy of the profile forming of the straight bevel gear can be greatly improved, the difference in the overall precision of the forging batch can be reduced, and the competition of the product is good. In turn, it can extend the life of the mold and many other features. In order to achieve the above-mentioned effects, the technical means adopted in the present invention is to form a preforming cavity in the pre-forging die, and form a final molding cavity in the final forging die, and the final molding cavity has a plurality of and each of the straight bevel gears. a second tooth cavity corresponding to the tooth portion, the second tooth cavity comprises two second involute surface tooth corridors which are curved faces, and the forged material is cut into a predetermined hybrid side pre-forging die required for molding (4) The preformed forgings are formed, and the preformed forgings are placed in the final forging die for forging, so that the preformed forgings are swollen and the final forging die is attached to the final forming cavity to form the involute toothed porch 201117895. The straight bevel gear product' wherein the preforming cavity has a plurality of first tooth cavities corresponding to each tooth of the straight bevel gear, and the first tooth cavity comprises two first involute teeth that are planar Profile, in order to reduce the flow of forging material in the final forging shape '俾 can greatly reduce the friction caused by the final forging die. [Embodiment] 基本• The basic features of the present invention 1.1 Straight bevel gear forging type method # Please refer to Figures 2, 7 and 8 'The invention is mainly for forging a pre-forging molding with a partial tooth profile 11 The forged piece l〇b is formed to reduce the wear of the final forming die 220 portion of the final forging die 22. In order to achieve the above effects, the forging method of the present invention comprises the following steps: (a) preparing a pre-forging die 21 and a final forging die 22, as shown in FIGS. 5 and 6, a preform is formed in the pre-forging die 21. a cavity 210; as shown in FIG. 7 and FIG. 8, a final molding cavity 220 is formed in the final forging die 22, and the final molding cavity 220 has a plurality of second tooth cavities 222, each of which is second. The tooth chamber 222 corresponds to each tooth portion of the straight bevel gear, the second tooth chamber 222 conforms to the entire tooth profile of the tooth portion, and the second tooth chamber 222 includes two second involute surface profiles. 221, the second involute surface profile 221 is a curved surface; (b) a forged material 10a is cut into a predetermined shape required for molding. (c) placing the forged material 10a into the pre-forging die 21 for forging to form a preformed forging piece 101(d) placing the formed forging piece 10b into the final forming hole of the final forging die 22 7 201117895 220 is forged, so that the preformed forging piece 1〇b is filled with the final forging die 22 and is attached to the final forming cavity 220 to form the straight bevel gear finished product having an involute profile. As shown in FIG. 5 and FIG. 6 , the main feature of the method of the present invention is that the preforming cavity 210 of the pre-forging die 21 has a plurality of first tooth cavities 213 , each of the first tooth cavities 213 and the Corresponding to each tooth portion of the straight bevel gear, the first tooth cavity 213 conforms to a local tooth profile of the tooth portion, the first tooth cavity 213 includes a first involute surface tooth profile 211, and the first The involute surface profile 211 is a flat surface, and after the forging material 10a is forged in the pre-forging die 21, the satin material is previously divided into materials, and the preformed forging piece 1b has the straight bevel gear The local tooth profile. As shown in FIG. 5 and FIG. 6, a specific embodiment of the straight bevel gear forging method of the present invention, the two first involute surface profiles 211 of the first tooth chamber 213 are connected by a first curved surface 212. . In a specific embodiment of the straight bevel gear forging method of the present invention, as shown in FIGS. 5 and 6, the two first involute surface profiles 211 of the first tooth cavity 213 of the pre-forging die 21 are in a first arc. Face 212 is connected. As shown in FIGS. 7 and 8, the second second involute surface 221 of the second tooth cavity 222 of the final forging die 22 is connected by a second curved surface 223, as shown in FIG. 9 and FIG. The face 212 is identical in shape to the second curved face 223. As shown in FIGS. 5 and 6, a specific embodiment of the 201117895 method for forging the straight bevel gear of the present invention, the pre-forging die 21 includes a first lower die 214' for placing the forged material 10a A punch 215' for impinging the forged material i〇a and being molded with the first lower mold 214 is disposed on the first lower mold 214. As shown in FIGS. 7 and 8, a specific embodiment of the straight bevel gear forging method of the present invention includes a second lower die 224' and a preform for the preformed forging member i〇b. A punch 225 for impacting the preformed forging member i〇b and being molded with the second lower mold 224, the final molding cavity 22 is disposed on the second Lu die 224. Referring to Figures 1, 2, 5 and 6, in the pre-forging step of the present invention, the forged material l〇a is placed in the pre-forging die 21 for forging, so that the forged material 1〇a is pre-divided to be Forging into a preformed forging 1b, the preformed forging 1b has a local tooth profile η of the bevel gear 10c, as shown in Figs. Referring to Figures 2, 4, 7 and 8 of the present invention, the final forging step of the present invention, the pre-formed forging l〇b is placed in a final forging die 22 for forging, so that the preformed forging 10b is full. The final forging die 22 is attached to the final forming cavity 22〇, and is then formed into a straight bevel gear 1〇c finished product having an involute profile. 1·2 Straight bevel gear forging molds, please refer to Figure 2, V and Figure 7. 'The straight bevel gear forging mold of the present invention is mainly used to produce straight bevel gears with less wear and better precision. Efficacy, the straight bevel gear forging mold includes a pre-forging die and a final forging die 22. 201117895 As shown in FIG. 5 and FIG. 6 'the pre-forging die 210, the forged material 10a is placed in the pre-forging die 21 to form a preformed die hole to form a preformed forged piece i〇b. As shown in Fig. 7 and Fig. 210, forging 00 and Fig. 8, the final forging die and 220 ^ 220 ^ second tooth cavity 222 and the tooth portion of the straight bevel gear are ten, δ hai first tooth The cavity 222 is in conformity with the entire tooth profile of the tooth portion, and the second tooth cavity 222 includes two second involute surface tooth profiles which are 1' the second involute surface tooth profile 221芍 A curved surface. Then, the preformed forging 1()b 卞iUb is placed into the final forging die 22, and the final forging/forging l〇b is full. The final forging die is attached to the final forming cavity 220.盍 1 female & 叩 叩 叩 is the finished product of the straight bevel gear with the involute profile 12 . The main feature of the mold of the present invention is that the mold cavity 21 () of the pre-premise 21 has a plurality of first tooth chambers 13' each of the molar chambers 213 and Each of the straight bevel gears corresponds to the tooth portion, and the first tooth cavity 213 conforms to a local tooth profile of the tooth portion, and the first tooth cavity 213 includes two first-involute surface profiles 21 and The first involute surface tooth profile 211 is a flat surface, and after the forging material 10a is forged in the pre-forging die 21, the satin material 10a is pre-divided into materials, and the pre-formed satin piece 1b is There is a local tooth profile of the straight bevel gear. For the operation of the preferred embodiment of the present invention, please refer to the pictures a to e in the second part of the annex. Firstly, the design parameters and simulation parameters of the straight bevel gear profile are set. As shown in Table 1 and Table 2 of Annex 1, the present invention is taken. With the 201117895 J UI gear tooth i, after the design parameters are available, the straight bevel gear A4 soft body developed according to the present invention can obtain the wheel geometry, and the pre-forged tooth profile can be added to the production with the present invention. Cm development time course. The pre-forging die tooth of the present invention is to reduce the involute surface of the final forging profile with a flat (four) tooth profile bevel, so that the pre-forging forming step + pre-compliance is used to separate the forging process, and most of the forging process is absorbed. Forming friction, reducing the service life of the final forging die _ consumption, increasing the forging die. Figures 2 to c of Figure 2 show a partial tooth profile of the preformed forging of the present invention for comparing the conventional forming process with the forming process of the developed pre-forging die of the present invention, as shown in Figure 2, Figure d, e. It is known from the forming process that the pre-forging die of the present invention has divided the material in the pre-forging forming step, so that in the final forging forming step, the final forging die is only for the purpose of expanding the involute surface profile to achieve Reduce the friction and forming process of traditional forging. In contrast, in the conventional forging forming process, the material and the tooth profile have not been divided during the preforming, so the forming process after the replacement of the final forging die is synchronous with the forming of the divided material, and the wear of the final forging die is severe. The invention is to form the split material from the pre-forging die to achieve the 'final forging die forming, the main purpose of expanding the tooth portion, to reduce the forming friction to reduce the wear caused by the final forging die' and thereby reduce the batch of forged gears. Accuracy covers the opposite sex. In order to reduce the abrasion of the mold tooth portion during the forging of the conventional straight bevel gear, the present invention replaces the involute surface portion of the straight bevel gear product in a plane in the toothed cavity portion of the pre-forging die. It is known from the simulation results that the 'pre-forging die can be effectively cut by the over-corrosion design of the chamfered plane' to reduce the forming friction of the final forging 1 11 201117895 ', in the final forging forming step, the material is filled with the inflation method. Attached to the final molding cavity, so it does not affect the desired product forming results. The basic concept of the finite element method is to discretize the original continuous domain, and then establish a set of linear equations by the equilibrium condition of the force, and discretize the stiffness matrix (Stiffness Matrix). ) By numerical solution, the displacement and stress of each unit and node can be obtained. In fact, it is to solve the complicated problem with a simpler problem. This method can use different material modes, such as rigid plastic mode, elastoplastic mode, and elastic-viscoplastic mode. After deriving the structural equations of each element, the boundary conditions are imported and the algebraic equation is obtained. At present, the finite element method has become the main method for metal plastic forming simulation. The problem of rigid plastic boundary value can be described as follows: set a rigid plastomer, the volume is V, the surface area is, under the force 6, the whole deformed body is in a plastic state, and the surface s is divided into two parts, \ and ~, where The given force S\ is given a speed v, °. It is defined by the following plastic equation and boundary conditions, namely: (1) Equilibrium differential equation °V"=0 (2-1) (2) Geometric equation (speed-strain rate relation equation) ευ = 2^+ν^ (2 -2) (3) Constitutive equation (stress-strain relationship equation) 12 201117895 3# ~ϊ§ σϋ ε... In the formula, σ and Sakixian stress and equivalent nuisance are expressed as (2-4) (2- 3) (4) 7 steel meets the VCinMlses drop criterion. The equivalent stress f and the equivalent strain rate # of the right angle coordinate system can be defined as follows: h#M+(K+(n)2+6(r2(2-5) t Team 畎«)]+ (2_6) Plastic flow stress Guan HQllQmon-Ludwik's law of rotation, ie σ = Κεη (2-7) According to the full strain theory of Levy-Mises flow law, the following relationship can be obtained between stress and strain. ^ =[^x~am]:[ay-am]:[az-aj 1 (2-8) where σ<Β=?(σ:+σ,+<τ) (5) SI elastic strain is not counted, Keeped by volume—^, at each point, must satisfy the following formula ' ε χ + ε> εζ = 〇 (2-10) (6) Boundary conditions, including force boundary conditions and velocity boundary conditions, respectively. m (2 -11) .
Vi = V/° SQS v (2-12) 式中，〜表示〜表面上任一點處單位外法向量的分量。 如圖十-所示，由材料成形過程與成形貞荷比較來看，:發明預 13 201117895 鍛模具在預成形與終鍛成形之間’預成型锻材在放置於終鍛成型模具 内時並不會因為間隙過大而導致擺放不均之結果，增加在實際上應用 之可行性；從成形負荷上來看傳統預鍛模具的預成形負荷較本發明 預鍛模具的爾形貞荷低，以能量絲看，鍛材在成形—雜模型所 需的能量是-_，那麼我們將—部分能量由預鍛模具來吸收，那麼 便可減少終锻模具的在成魏財的能量負載，達到減少齒部 需求。 肆•結論 ^本發明藉由上述技術特徵之建置確實可以使大部分鍛材 机動產生的摩擦力由預锻模具來承受，以減少鍛材在終鍛成型 的机動量’而可大幅降低摩擦力對終锻模具所造成磨損，因而 、有大巾胃提升直㈣輪之財卩成龍度、減少锻造批量整體精 :的差異性’並可提升產品競爭力佳進而得以延長模具使用 壽命等諸多的特點。 以上所述，僅為本發明之一可行實施例，旅邡用以限定本 發明之專利範圍’舉凡依據下列申請專利範圍所述之内容、特 徵以及其精神而為之其他變化的等效實施，皆應包含於本發明 之專利範圍内。本發明之機構，除上述優點外，旅深具產業之 利用〖生，可有效改善習用所產生之缺失，而且所異體界定於申 請專利範®之特徵，未見於同類物品，故而具實難與進步性 已符合發明專利要件，爰依法具文提出申請，謹請鈞局依 201117895 去核予專利，以維護本申請人合法之權益。 【圖式簡單說明】 圖一係傳統直傘齒輪鍛造過程示意圖。 圖二係本發明直傘齒輪鍛造過程示意圖。 圖三係圖二A區域之局部放大示意圖。 圖四係圖二B區域之局部放大示意圖。 圖五係本發明預鍛模具之外觀示意圖。 圖六係圖五C區域之局部放大示意圖。 圖七係本發明終锻模具之外觀示意圖。 圖八係圖七之D區域局部放大示意圖。 圖九係本發明預鍛模具另—實施之局部放大示意圖。 圖十係本發明終鍛模具另—實施之局部放大示意圖。 圖十-係本發明與傳統預鍛模具成形負荷之比較圖。 附件一：表-縣發明直傘齒輪齒廓設計參數；表二係本發明 模擬軟體設定參數。 附件二：圖片（a)預成型齒形與終锻齒形比較圖；圖片⑹預成 型鍛胚圖；圖片⑹終锻成魏圖片⑷傳統鍛造成型過 程圖；圖片（e)本發明模具設計成型過程圖。 【主要元件符號說明】 (10a)锻材 (l〇c)直傘齒輪 (l〇b)預成型鍛件 (11)局部齒廓 15 201117895 4 (211)(12)(221)漸開面齒廓 • (210)預成型齒形模穴 (213)(222)齒腔 (215)(225)衝頭 (220)終成型模穴 (21) 預鍛模具 (212)(223)弧面 (214)第一下模 (22) 終鍛模具 (224)第二下模Vi = V/° SQS v (2-12) where ～ represents the component of the normal vector outside the unit at any point on the surface. As shown in Figure 10, the material forming process is compared with the forming load: Inventive 13 201117895 Forging die between preforming and final forging, when the preformed forged material is placed in the final forging die The result of uneven placement is not caused by the excessive gap, and the feasibility of the application is increased. From the forming load, the preforming load of the conventional pre-forging die is lower than that of the pre-forging die of the present invention. According to the energy wire, the energy required for the forging material in the forming-hybrid model is -_, then we will absorb part of the energy from the pre-forging die, then we can reduce the energy load of the final forging die in Wei Cai, and reduce it. Tooth needs.肆•Conclusion^ The invention can ensure that the friction generated by most of the forging materials can be withstood by the pre-forging die to reduce the maneuvering amount of the forged material in the final forging by the construction of the above technical features, and the friction can be greatly reduced. The force causes wear and tear on the final forging die. Therefore, there is a big towel stomach to improve the straightness of the straight (four) rounds, reduce the difference in the overall precision of the forging batches, and improve the competitiveness of the product and thus extend the service life of the mold. specialty. The above is only one of the possible embodiments of the present invention, and the equivalent of the scope of the patents of the present invention is defined by the following claims, All should be included in the scope of the patent of the present invention. In addition to the above advantages, the mechanism of the present invention has the advantage of utilizing the industry, which can effectively improve the lack of use, and the characteristics of the patent application defined in the patent model are not found in the same kind of articles, so it is difficult to Progressiveness has been in line with the patent requirements of the invention, and the application has been filed in accordance with the law. The Department of Health is requested to approve the patent in accordance with 201117895 to protect the legitimate rights and interests of the applicant. [Simple diagram of the figure] Figure 1 is a schematic diagram of the forging process of a conventional straight bevel gear. Figure 2 is a schematic view of the forging process of the straight bevel gear of the present invention. Figure 3 is a partial enlarged view of the area of Figure 2A. Figure 4 is a partial enlarged view of the area of Figure 2B. Figure 5 is a schematic view showing the appearance of the pre-forging die of the present invention. Figure 6 is a partial enlarged view of the fifth C area. Figure 7 is a schematic view showing the appearance of the final forging die of the present invention. Figure 8 is a partial enlarged view of the D area of Figure 7. Figure 9 is a partially enlarged schematic view showing another embodiment of the pre-forging die of the present invention. Figure 10 is a partially enlarged schematic view showing the implementation of the final forging die of the present invention. Figure 10 is a comparison of the forming load of the present invention with a conventional pre-forging die. Annex I: Table-County Invented Straight Bevel Gear Tooth Profile Design Parameters; Table 2 is the simulation software setting parameters of the present invention. Attachment 2: Picture (a) Comparison of pre-formed tooth shape and final forging tooth shape; Picture (6) Pre-formed forged embryo drawing; Picture (6) Final forging into Wei picture (4) Traditional forging type process picture; Picture (e) Mold design and molding of the invention Process diagram. [Main component symbol description] (10a) Forged material (l〇c) Straight bevel gear (l〇b) Preformed forging (11) Local tooth profile 15 201117895 4 (211)(12)(221) Involute surface profile • (210) Preformed tooth cavity (213) (222) Tooth cavity (215) (225) Punch (220) Final forming cavity (21) Pre-forging die (212) (223) Curved surface (214 ) first lower die (22) final forging die (224) second lower die
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