非圆锥齿轮冷摆辗精密成形技术基础研究

By now, the research on precision plastic forming theory and technology of non-circular bevel gear is blank. Thus, the non-circular bevel gear is mainly milled by five-axis linkage CNC machine tools and it cannot achieve the precision plastic forming. Aimed at the above status, this project proposes to carry out the fundamental research on cold rotary forging technology of non-circular bevel gear. Through the theoretical calculation, FE simulation and experiment, the plastic deformation laws and mechanical conditions in cold rotary forging of non-circular bevel gear are analyzed and its plastic deformation and forming mechanisms are revealed. The evolution mechanisms of tooth accuracy of non-circular bevel gear under the complex non-uniform deformation conditions are revealed and the methods for die cavity correction are proposed to improve the tooth accuracy and its consistency. The microstructure evolution mechanisms of non-circular bevel gear are analyzed and the interactive mechanisms of macro-deformation and microstructure of non-circular bevel gear in cold rotary forging are clarified. The coordination control methods for tooth accuracy and microstructure are established. Based on the above analysis, the precision forming theory, technological design methods and forming quality control methods for cold rotary forging of non-circular bevel gear are established. This project has a significant scientific value and practical importance for establishing the scientific theory of cold rotary forging of non-circular bevel gear，developing the key technological methods for high efficiency and high quality cold rotary forging of non-circular bevel gear and promoting the development and application of non-circular bevel gear mechanisms and equipment.

针对非圆锥齿轮精密塑性成形理论和技术研究空白，以致目前非圆锥齿轮主要采用五轴联动数控加工中心切削加工，还不能实现精密塑性成形制造的现状，本项目提出开展非圆锥齿轮冷摆辗精密成形技术基础研究。通过理论计算、有限元模拟和冷摆辗实验，研究非圆锥齿轮冷摆辗塑性变形规律和成形力学条件，揭示非圆锥齿轮冷摆辗塑性变形和成形机制；揭示复杂不均匀变形条件下非圆锥齿轮冷摆辗齿形精度演化机理，建立提高齿形精度及齿形精度一致性的冷摆辗模具型腔修正方法；研究非圆锥齿轮冷摆辗微观组织演化机理，阐明非圆锥齿轮冷摆辗宏观变形与微观组织交互作用机制；建立非圆锥齿轮冷摆辗齿形精度和组织性能协同控制方法，建立非圆锥齿轮冷摆辗精密成形理论、技术设计方法和成形质量控制方法。本项目研究对于构建非圆锥齿轮冷摆辗精密成形科学理论，发展非圆锥齿轮高效优质冷摆辗精密成形关键技术方法，促进非圆锥齿轮机构装备开发应用具有重要的学术价值和实际意义。

针对非圆锥齿轮精密塑性成形理论和技术研究空白，以致目前非圆锥齿轮主要采用五轴联动数控加工中心切削加工，还不能实现精密塑性成形制造的现状，本项目开展了非圆锥齿轮热锻/冷摆辗精密成形技术基础研究。通过理论计算、有限元模拟和精密成形实验，研究了非圆锥齿轮精密成形过程中金属流动规律、模具充填规律以及各变形区相互影响和变形协调规律，建立了非圆锥齿轮精密成形塑性失稳、塑性穿透等力学模型和条件，实现了非圆锥齿轮可精密成形。建立了非圆锥齿轮精密成形精度预测模型，揭示了模具弹性变形和齿轮卸载回弹变形对非圆锥齿轮精密成形精度的影响规律，阐明了模具-非圆锥齿轮几何精度遗传机理，提出了基于系统误差调控和模具修正协同的非圆锥齿轮精密成形精度控制方法。揭示了精密成形-热处理锥齿轮微观组织形貌、织构以及位错等演化规律，提出了加热-渗碳-正火-淬火热处理新工艺，实现了精密成形锥齿轮微观组织有效控制。提出了非圆锥齿轮精密成形工艺设计方法，实现了非圆锥齿轮精密成形制造。研究结果为高性能非圆锥齿轮精密成形精度和微观组织控制、工艺优化设计和工程应用提供了重要的理论依据和技术支撑。.在上述研究基础上，本项目在国内外学术刊物上共发表学术论文 13 篇，其中 SCI收录 11 篇；授权中国发明专利 4 项，申请中国发明专利 3 项；参加国际国内学术会议6次；培养毕业博士2 名（其中1篇博士学位论文获第8届上银优秀机械博士论文奖优秀奖、2019年中国汽车工程学会博士学位论文优秀奖），毕业硕士 3 名，在读博士1名，在读硕士 2 名。本项目完成了计划书中的各项指标。