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.

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