花键轴增量式滚轧成形工艺的分流方式及温度效应研究

摘要

To reduce the negative effect of initial workpiece diameter on the rolling load and tooth filling quality, a tooth divided flow method is put forward according to the thought of divided flow forging, and the relevant numerical analysis and verification are conducted with DEFORM-3D. Furthermore, the temperature effect on the rolling load and tooth filling quality is investigated. The results show that after the tooth divided flow method is applied, the maximum rolling load during calibrating phase can be lowered by 60% averagely, the tooth filling quality and pitch cumulative error can be improved obviously. Due to the temperature effect, the maximum rolling load is reduced by 20%, 67% and 80% respectively under 400 ℃, 800 ℃ and 1 000 ℃ compared with the case under material temperature of 20 ℃, and also the tooth filling quality is improved.%为了降低花键轴增量式滚轧成形工艺中工件初始直径对滚轧载荷和齿形填充质量的负面影响,根据分流锻造思想提出了一种齿顶分流方式,分析了温度效应对滚轧载荷和齿形填充质量的影响,并通过DEFORM-3D有限元软件对该分流方式进行了数值分析验证.研究结果表明:在校正滚轧阶段,齿顶分流方式的应用使得花键轴增量式滚轧成形工艺中滚轧载荷最大值平均下降了约60％,并降低了工件初始直径对花键轴齿形填充质量和齿距累计误差的影响.工件材料在400、800、1 000℃(相对室温20℃)时,温度效应使得最大滚轧载荷分别平均下降了约20％、67％、80％,并且明显提高了齿形处工件材料的填充质量.