Profile Accuracy Control Method of Straight Bevel Gear by Near Net Shape Process Based on Numerical Calculation

Abstract

Abstract:

For the problem that tooth profile accuracy was not required high and modification was not full of consideration in straight bevel gear plastic forming process, a straight bevel gear tooth profile accuracy control method was proposed with near net forming based on the numerical calculation, then a detailed description of the process was carried out. The car differential planetary gear was studied by digital modeling, contact analysis, forming process finite element simulation and springback law calculation. The results display that the minimum rebound appears at drum and gradually increase to the tooth point or tooth root in the height of tooth direction. Maximum springback is up to maximum 0.14mm, and minimum 0.02mm closed to the tooth top. Twice modification was carried out to control accuracy of tooth profile and the maximum deviation value is up to -0.025mm while the minimum was close to zero. The results show that this method can use the near net shape process to obtain higher profile accuracy straight bevel gear products.

Key words: straight bevel gear, near net shape, numerical calculation, profile accuracy, axial modification

摘要：

针对塑性成形的直齿锥齿轮齿形精度不高、修形考虑不足的问题，提出了一种基于数值计算的近净成形齿形精度控制方法，并详细描述了其工艺流程。以轿车差速器行星锥齿轮为对象进行应用研究，进行了直齿锥齿轮的数字化建模、接触分析、塑性成形工艺有限元仿真和回弹计算。结果显示，在齿高方向上，回弹最小在鼓形处，往齿顶和齿根方向回弹量逐渐增大，接近齿顶处达到最大回弹0.14mm。对模具型腔进行了二次修正的精度控制，使齿形偏离理论修形齿面的值降到-0.025mm以下。研究结果表明，采用该方法能够获得具有较高齿形精度的直齿锥齿轮产品。

关键词: 直齿锥齿轮, 近净成形, 数值计算, 齿形精度, 轴向修形

CLC Number:

TG315.2

Xu Hongbin, Hu Jianjun, Zhang Weiqing, Ling Wenkai. Profile Accuracy Control Method of Straight Bevel Gear by Near Net Shape Process Based on Numerical Calculation[J]. China Mechanical Engineering, 2014, 25(17): 2386-2390.

许洪斌, 胡建军, 张卫青, 凌文凯 . 基于数值计算的近净成形直齿锥齿轮齿形精度控制方法[J]. 中国机械工程, 2014, 25(17): 2386-2390.

References

[1]张清萍，尚勇，王玉增，等.双联齿轮精锻成形工艺及数值模拟分析[J].中国机械工程，2006，17(增刊1)：119-121.
Zhang Qingping, Shang Yong, Wang Yuzeng, et al. Numerical Simulation of Precision Forging Process for Duplicate Gear[J]. China Mechanical Engineering，2006，17(S1):119-121.
[2]Rosochowski A，Balendra R. Secondary Yielding of Forged Component Due to Unloading[J]. Journal of Materials Processing Technology，2001,115:233-239.
[3]林雪，张耀宗，方泉水，等.高精度锥齿轮冷闭式锻造齿模修形及加工电极设计[J].锻压技术，2006，31（6）：80-84.
Lin Xue, Zhang Yaozong, Fang Quanshui, et al. Profile Modification of Cavity Die and the Electrode Design for Precision Bevel Gear in Cold Closed-forging Process[J]. Forging and Stamping Technology,2006，31（6）：80-84.
[4]张卫青，郭晓东，张明德，等.锥齿轮测量齿面接触分析方法研究[J].机械传动，2010，34(7)：5-8.
Zhang Weiqing, Guo Xiaodong, Zhang Mingde, et al. The TCA Methods of Measured Tooth Surface of Spiral Bevel Gear[J]. Journal of Mechanical Transmission, 2010，34(7)：5-8.
[5]凌文凯，许洪斌，胡建军.直齿锥齿轮冷精锻工艺的优化设计[J].锻压技术，2012，37（5）:176-179.
Ling Wenkai, Xu Hongbin, Hu Jianjun. Optimization Design of Precision Cold Forging for Spur Bevel Gear[J]. Forging and Stamping Technology, 2012，37（5）:176-179.
[6]许洪斌,胡建军,张卫青,等.一种冷成形直齿锥齿轮齿形尺寸精度的控制方法:中国. 201210161894[P]. 2012-10-17.
[7]胡成亮，刘全坤，赵震，等.考虑弹性变形行为的齿形凹模修正方法[J].上海交通大学学报，2009，43（1）：52-55，60.
Hu Chengliang, Liu Quankun, Zhao Zhen. Modification Method of Gear-shaped Die Considering Elastic Deformation Behavior[J]. Journal of Shanghai Jiaotong University, 2009，43（1）：52-55，60.
[8]凌文凯.直齿锥齿轮成形工艺及精度控制研究[D].重庆：重庆理工大学，2012.
[9]邓陶勇.直齿轮冷精锻模具弹性变形规律及修正[D].合肥：合肥工业大学，2007.

[1]	LI Junliang;WANG Shilong;WANG Sibao;XIA Changjiu. Energy Consumption Model of Hobbing Machine Tools Based on Workpiece Material Removal Rate [J]. China Mechanical Engineering, 2020, 31(21): 2626-2631.
[2]	TANG Xinzi;XIAO Peng;CAI Peng;PENG Ruitao. Multi-objective Optimization Design of Small-centrifugal Compressor under Variable Flow Conditions [J]. China Mechanical Engineering, 2018, 29(16): 1975-1983.
[3]	XING Shikai, LI Juxia, MA Chaochen, CHEN Lihui, LI Qing. Optimal Design for Regulating Mechanisms of Variable Radial Turbocharger [J]. China Mechanical Engineering, 2017, 28(02): 139-143,149.
[4]	Xie Chao, Gu Zhengqi, Yang Zhendong, Yang Xiaotao, Zong Yiqi, Luo Zemin. Analysis on Aerodynamic Noise Characteristics of Multi-blade Centrifugal [J]. China Mechanical Engineering, 2014, 25(19): 2658-2664.
[5]	LV Jian-Gang, GAO Fei, BAI Xiang-Hua, LI Pan-Lu. #br# Simulation Analysis and Experimental Research on Movements of Biomimetic Propulsion Unit Based on Basilisk Lizard [J]. China Mechanical Engineering, 2013, 24(15): 2048-2052,2059.
[6]	WANG Yan-An, WEN Gui-Lin, CHEN Zhi-Fu, WANG Meng. A Multipole Galerkin Boundary Element Method for Two Dimensional Half Space Acoustic Problems [J]. China Mechanical Engineering, 2013, 24(15): 2066-2071.
[7]	CA An-Jiang, ZHANG Zhen-Jun, RUAN Xiao-Guang. Pressure Angle Values Based on Shaving Modification Terms [J]. China Mechanical Engineering, 2013, 24(10): 1327-1330.
[8]	LIU Qiang-Ling. Study on Deflection of a Variable Cross Sectional Flexible Component under Arbitrary Loads [J]. China Mechanical Engineering, 2013, 24(10): 1381-1384.
[9]	MA Wei-Jin-1, LI Feng-Lan-2, WANG Dun-Yuan-1, XIONG Shi-Bei-2. Modelling and Validation of Vertical Vibration with 6 Degrees of Freedom for 4-high Hot Strip Mill Stand [J]. China Mechanical Engineering, 2011, 22(24): 2962-2965.
[10]	LI Wei-Wei, CHEN Xiao-Yang, CHEN Xue-Jin. Numerical Calculation and Roller Pressure Analysis of Theoretical Logarithm Profile Equation [J]. China Mechanical Engineering, 2011, 22(15): 1788-1792.
[11]	Zhang Kunpeng;Ding Qian. Vibration Analysis of a Two-disc Rotor-stator System with Axial Rubs [J]. J4, 2009, 20(21): 0-2627.
[12]	Tong Junjie, ;Xu Jinliang;Cen Jiwen. Numerical Calculation and Experiments of Micro Nozzle’s Impinging Force [J]. J4, 2009, 20(17): 0-2112.
[13]	Chen Ming;Pu Jianing. Godunov-type Solutions with Second Order in Time and Space for Fluid Structure Interaction Model of Liquid-filled Pipeline [J]. J4, 2009, 20(11): 0-1292.
[14]	Luo Zhigao;Fan Binbin;Guo Xiaodong;Wang Xiang;Li Ju. Analysis of the Three-dimensional Melting Flow in Injection Cavity Based on the Wavelet Finite Element [J]. J4, 2009, 20(10): 0-1140.
[15]	Hua Lin;Huang Hailang;Han Xinghui;Feng Wei. Research on the Method of Profile Modification by Circular Curve for Involute Straight Bevel Gear [J]. J4, 2009, 20(07): 0-881.