Process Analysis of Cold Occlusive Precision Forging for a Certain Type of Planetary Gear

Abstract

Abstract:

Combined with numerical simulation and physical experiments, a study of differential planetary gear formed by occlusive cold extrusion was conducted. The deformation process, metal flow field and forming load were analyzed. And based on the floating die technology, the combination structure of three dies was designed. The results show that the small end of tooth is first filled, and the presence of overflow tank at the top of the large end of tooth significantly improves the metal flow conditions. Compared to the absence of overflow tank, the total forming load reduces from 9550kN to 5576kN and the clamping force reduces 50.72%, only as 2464kN. Finally, the experiments were conducted and the results show that the gear is full filled with smooth surface.

Key words: planetary gear, occlusive extrusion, clamping force, combination die

摘要：

采用数值模拟和物理实验相结合的方法开展了差速器行星齿轮闭塞式冷成形工艺研究，深入分析了变形过程、金属流动场、成形载荷等，并基于浮动凹模技术设计了三层组合凹模结构。模拟结果表明：金属首先充填小端齿形，且大端齿顶溢流槽的存在显著改善了成形末期金属的流动状态，相比无溢流槽时总成形载荷由9550kN减小至5576kN，合模力减小50.72%，仅为2464kN。最后，进行实验试制，所得齿轮齿形充填完整，表面光洁，无需机加工，成形质量较好。

关键词: 行星齿轮, 闭塞式, 合模力, 组合凹模

CLC Number:

TG316

Wang Jiulin, Li Ping, Tian Ye, Xue Kemin, Wang Changkai. Process Analysis of Cold Occlusive Precision Forging for a Certain Type of Planetary Gear[J]. China Mechanical Engineering, 2016, 27(05): 698-703.

王久林, 李萍, 田野, 薛克敏, 汪长开. 某型号行星齿轮冷闭塞精锻成形工艺分析[J]. 中国机械工程, 2016, 27(05): 698-703.

References

[1]马国华,郭学东. 差速器锥齿轮冷模锻数值模拟及成形性能研究[J]. 锻压技术,2008,33(4):133-136.

Ma Guohua, Guo Xuedong. Analysis on Numerical Simulation and Forming Properties of Bevel Gear Used in Car Differential Gear Box[J]. Forging & Stamping Technology, 2008,33(4):133-136.

[2]伍太宾,任广升. 汽车差速器锥齿轮的温锻制坯/冷摆辗成形加工技术研究[J]. 中国机械工程,2005, 16(12):1106-1109.

Wu Taibin, Ren Guangsheng. Research on Warm Forging/cold Orbital Forming Technology for the Straight Bevel Gear in Differential Case[J]. China Mechanical Engineering, 2005, 16(12):1106-1109.

[3]尹海星. 伞齿轮冷摆辗精密成形工艺研究及其CAD/CAPP系统开发[D]. 武汉：武汉理工大学,2002.

[4]Ekkeh K, Richard K. Possibilities of Warm Extrusion in Combination with Cold Extrusion[J].Journal of Materials Processing Technology,1991,35:451-456.

[5]Bdul N A, Dean T A. An Analysis of the Forging of Spur Gear Forms[J]. Int. Mach. Tool Desres., 1986,26(2):113-123.

[6]Saravanan N, Ramachandran K I. Fault Diagnosis of Spur Bevel Gear Box Using Discrete Wavelet Features and Decision Tree Classification[J]. Expert Systems with Applications,2009,36(5): 9564-9573.

[7]张勇. 汽车设计齿轮分类方案比较分析[J].现代商贸工业,2009,21(19):292-293. Zhang Yong. Comparative Analysis of Automotive Design Gear Classification Scheme[J]. Modern Business Trade Industry, 2009,21(19):292-293.

[8]Kondo K,Ohga K. Investigations on Cold Die Forging of a Gear Utilizing Divided Flow[J]. Bulletin of JSME,1986,28(244):2442-2450.

[9]靳辅安,苏升贵,高彩,等.十字头锻件挤压成形的研究[J]. 金属科学与工艺,1983,2(3)：82-91.

Jin Fuan, Su Shenggui, Gao Cai, et al. A Study on the Extruding Processes of Cross-spiders[J]. Metal Science and Technology, 1983,2(3)：82-91.

[10]杨慎华,寇淑清,赵勇,等. 伞齿轮冷闭塞锻造成形过程数值仿真[J]. 农业机械学报,2003,34(2): 117-120.

Yang Shenhua, Kou Shuqing, Zhao Yong, et al. Numerical Simulation of Cold Closed-die Forging of Bevel Gears[J]. Agricultural Machinery, 2003,34(2): 117-120.

[11]娄华威,高锦张. 基于厚壁圆筒理论的组合凹模优化设计[J]. 机械制造与自动化,2003(1):16-19.

Lou Huawei,Gao Jinzhang. The Optimum Design of Composed Concave Die by Thick-walled Cylinder Theories[J]. Mechanical Manufacturing and Automation, 2003(1):16-19.

[12]刘彦国,张红岩. 组合凹模应力应变分析[J]. 机械研究与应用,2004,17(3):45-47.

Liu Yanguo, Zhang Hongyan. Stress and Strain Analysis of Combination Die[J]. Mechanical Research & Application, 2004,17(3):45-47.

[13]陈再良,陈蕴博,佟晓辉,等. 典型冷作模具钢性能与失效关系的探讨[J]. 金属热处理,2006,31(2): 87-93.

Chen Zailiang, Chen Yunbo, Tong Xiaohui, et al. Mechanical Properties and Failure Types for Cold-working Die Steels[J]. Metal Heat Treatment, 2006,31(2): 87-93.

[14]周琨,陈国学. 伞齿轮精密成形模具变形的数值模拟分析[J]. 塑性工程学报,2002,9(1):74-77.

Zhou Kun, Chen Guoxue. Numerical Simulation Analysis of Die Deflection in Net Shape Forming of Bevel Gear[J]. Journal of Plasticity Engineering,2002,9(1):74-77.

[1]	LIU Junlong1;SUN Dongye1;LIU Xiaojun1;YE Ming2;YOU Yong1. Study on Dynamic Response Characteristic Simulation of EMCVT Actuators [J]. China Mechanical Engineering, 2020, 31(03): 253-260.
[2]	RUI Xiaoming;YIN Wenliang. Research on Transmission Performances of Wind Turbines with Differential Speed Regulation [J]. China Mechanical Engineering, 2019, 30(09): 1034-1040.
[3]	JIN Qi, WANG Youren, WANG Jun. Planetary Gearbox Fault Diagnosis Based on Multiple Feature Extraction and Information Fusion Combined with Deep Learning [J]. China Mechanical Engineering, 2019, 30(02): 196-204.
[4]	WANG Youren;WANG Jun;HUANG Haian. Fault Diagnosis of Planetary Gearboxes Based on NLSTFT Order Tracking under Variable Speed Conditions [J]. China Mechanical Engineering, 2018, 29(14): 1688-1695.
[5]	YU Jun1，2;YU Deshui1. Applications of Flow Graph to Fault Diagnosis of Planetary Gearboxes [J]. China Mechanical Engineering, 2018, 29(10): 1208-1213.
[6]	WANG Xuan1,2;WANG Xiyang1. Measurement and Analysis of Torsional Vibration Signals for Diagnosing Planetary Gearbox Faults [J]. China Mechanical Engineering, 2018, 29(01): 49-56.
[7]	Huang Jinying, Du Weimin, Li Hui, Jiang Zhihong, Yang Huan. Dynamic Simulation for a Three-arm Robot on Orbit [J]. China Mechanical Engineering, 2016, 27(03): 328-333.
[8]	Ye Ming, Li Xin, Luo Yong. Performance Analysis of Variable Clamping Force Actuator of EMCVT [J]. China Mechanical Engineering, 2015, 26(3): 398-402,413.
[9]	Li Sheng;Wu Qingming;Zhang Zhiqiang;Chen Chongming. Bifurcation and Chaos Characteristics of Two-stage Planetary Gear Train Sets [J]. China Mechanical Engineering, 2014, 25(7): 931-937.
[10]	Hao Yunzhi1;Sun Dongye2;Lin Yupei1,2. Reliability Analysis of Continuously Variable Transmission Clamping Force Control Algorithm [J]. China Mechanical Engineering, 2014, 25(12): 1687-1693.
[11]	HU Gui-Feng, WANG Xi-Xiang. Planetary Gear Signal Acquisition Technology Based on Time-Domain Synchronous Average Method [J]. China Mechanical Engineering, 2013, 24(6): 787-791.
[12]	SHU Hua-Jun, HU Li-Zhong. #br# Sensitivity Analysis of Permanent Magnetic Planetary Gear Drive [J]. China Mechanical Engineering, 2013, 24(4): 468-476.
[13]	QIN Da-Tong-1, YANG Jun-1, 2, ZHOU Zhi-Gang-1, 3, CHEN Hui-Chao-1. Dynamics Characteristic of Planetary Gear System of Wind Turbines under Varying Load [J]. China Mechanical Engineering, 2013, 24(3): 295-301.
[14]	YANG Jun, ZHANG Li-Ping. Varying Load Incentive Dynamics Model and Response Characteristic of Planetary Gear System of Wind Turbine [J]. China Mechanical Engineering, 2013, 24(13): 1783-1788,1795.
[15]	BO Lei, WANG Yin, HUANG Wei-Qing, ZHANG Qing. Study on Multi-foot Clamping Piezoelectric Linear Motor [J]. China Mechanical Engineering, 2013, 24(08): 1080-1084.