斜齿圆柱齿轮旋转精冲成形机理及工艺方法研究

As one of the most novel methods to manufacture helical gear, Rotating Fine-blanking technique will be investigated and studied in this proposal. The basic forming mechanism and process design method of Rotating Fine-blanking technique for helical gear production will be revealed through elastic-plastic mechanics analysis, deformation and kinematic analysis as well as physical simulation experiments and forming process tests. The scientific problem including mechanics, kinematics and materials evolution during Rotating Fine-blanking process will be studied. The materials flow and plastic forming law of the workpiece during Ratating Fine-blanking will be observed and revealed by experiments and calculation. In addtion, the microstructure evolution of materials during Rotating Fine-blanking process will be studied. Relationship between the mechnical performance of the helical gear and microstructure of the materials will be revealed by physical experiments and technology of materials performance measurement. The mechanical principle of Rotating Fine-blanking die will be also studied and the proper method to design the Rotating Fine-blanking die will be developed. The intelligent and systematic processing design method for Rotating Fine-blanking technology will be established and the optimized process parameters will be calculated. Research results will provide a reliable basic theory and process design method for manufacturing helical gear by Ratating Fine-blanking technique.

以斜齿圆柱齿轮旋转精冲新技术为研究对象，通过弹塑性力学分析、变形体运动学分析以及成形物理模拟试验和成形工艺试验，解决斜齿圆柱齿轮旋转精冲力学、运动学以及材料学科学问题。揭示斜齿圆柱齿轮旋转精冲制造过程材料流动及塑性成形规律、模具运动学规律、产品成形工艺力学条件以及成形稳定性条件；研究斜齿圆柱齿轮旋转精冲制造过程中材料组织演化规律及其影响因素；揭示斜齿圆柱齿轮旋转精冲制造过程产品成形质量、几何精度同材料属性、产品几何参数以及旋转精冲工艺参数之间的耦合关系；分析旋转精冲模具机构学原理，掌握旋转精冲模设计方法；开展斜齿圆柱齿轮旋转精冲工艺优化方法研究，开发斜齿圆柱齿轮旋转精冲工艺智能设计系统，实现斜齿圆柱齿轮旋转精冲工艺设计及过程优化控制，为高性能高精度斜齿圆柱齿轮的旋转精冲制造提供可靠的理论支撑和设计方法。研究成果对于促进斜齿圆柱齿轮旋转精冲新技术理论及应用发展具有重大意义。

斜齿圆柱齿轮广泛应用于机械、交通、能源等领域，传统斜齿轮制造采用“锻造制坯-机械加工”的生产方式，其生产工序复杂、生产率低、材料利用率低，在机械切削加工的同时金属纤维被切断，削弱了齿轮机械强度。为避免传统齿轮加工技术的缺点与产品缺陷，本项目对斜齿圆柱齿轮旋转精冲技术进行深入研究。本项目建立了斜齿圆柱齿轮旋转精冲有限元模拟模型，并设计制造了斜齿圆柱齿轮旋转精冲工装与模具，进行了斜齿圆柱齿轮旋转精冲成形实验，通过有限元模拟与成形实验，研究了斜齿圆柱齿轮旋转精冲变形机理及旋转精冲斜齿圆柱齿轮的内部微观组织，获得了斜齿圆柱齿轮旋转精冲成形工艺影像规律及工艺模具设计方法，揭示了旋转精冲过程中模具磨损规律与机理，并对超声波辅助感应淬火提高模具耐磨损性能进行了研究。通过项目研究，揭示了斜齿圆柱齿轮旋转精冲机理，获得了斜齿圆柱齿轮旋转精冲工艺模具设计方法，成功实现了斜齿圆柱齿轮的旋转精冲成形，实验得到的斜齿圆柱齿轮高度为4mm，倾斜角为10°，剪切断面为全光亮带，且塌角尺寸仅为料厚的10.5%，研究结果验证了本项目提出的旋转精冲斜齿圆柱齿轮的可行性。采用本项目工艺能极大的提高斜齿圆柱齿轮的加工效率和齿轮质量，本项目研究也为将此先进的塑性成形工艺进一步产业化应用提供了技术与理论指导。