| 560 | 3 | 38 |
| 下载次数 | 被引频次 | 阅读次数 |
齿轮是传动系统的核心基础件，被广泛应用于机械、汽车、航空航天装备等领域。齿轮传统制造技术为切削加工，其材料利用率低、加工周期长，特别是金属流线切断，损害齿轮性能，无法满足高端装备发展需求。齿轮精密塑性成形制造技术具有节能、节材、高效和优质等特点，是高性能齿轮技术发展方向。阐述了齿轮精密塑性成形理论方法，分析了国内外圆锥直齿轮、圆柱直齿轮和圆柱螺旋/斜齿轮精密成形技术特点；介绍了齿轮精密成形典型装备及产线，总结了齿轮无切削摆辗精密成形和锻造精密成形应用情况。此外，展示了圆锥螺旋齿轮多自由度包络成形和非圆齿轮锻造成形新方法，为高性能齿轮无切削成形制造技术装备研究与应用提供了参考。
Abstract：Gears are widely used in machinery, automobile and aerospace equipment industries as the core foundation parts of transmission system. Traditional manufacturing technique for gear is metal cutting process, with low material utilization and long processing cycle, especially metal flow lines are cut off, which damages gear performance and cannot meet the development needs of high-end equipment.Gear precision plastic forming manufacturing technology has the characteristics of energy saving, material saving, high efficiency and high quality, which is the development direction of high performance gear manufacturing.The gear precision plastic forming theory method was described, and the characteristics of the precision forming technology for bevel spur gear, cylindrical spur gear and cylindrical helical gear at home and abroad were analyzed. The typical gear precision forming equipments and production lines were introduced, and the applications of gear rotary forging precision forming without cutting and forging precision forming were summarized. Besides, the new methods of multi-freedom envelope forming for bevel helical gear, and forging for non-circular gear were presented, which provide a reference for the researches and applications of technologies and equipments of high performance gear manufacturing without cutting.
[1] 华林，韩星会，冯玮.齿轮精密塑性成形理论与技术[M].武汉：湖北科学技术出版社，2021.HUA Lin,HAN Xinghui,FENG Wei.Theory and technology of gear precision plastic forming[M].Wuhan:Hubei Science and Technology Press,2021.
[2] 夏巨谌.典型零件精密成形[M].北京：机械工业出版社，2008.XIA Juchen.Precision forming of typical parts[M].Beijing:China Machine Press,2008.
[3] 胡亚民，付传峰，赵军华.精锻成形技术60年的发展与进步 [J].金属加工(热加工),2010,(15):1-5.HU Yamin,FU Chuanfeng,ZHAO Junhua.The development and progress of precision forging forming technology in 60 years[J].Metal Working (Hot Working) ,2010,(15):1-5.
[4] 王忠雷，赵国群.精密锻造技术的研究现状及发展趋势[J].精密成形工程，2009,1(1):32-38.WANG Zhonglei,ZHAO Guoqun.Recent condition and developing trends of precise forging technology[J].Netshape Forming Engineering,2009,1(1):32-38.
[5] DEAN T A.The net-shape forming of gears[J].Materials & Design,2000,21(4):271-278.
[6] 江雄心，万平荣，林治平.直齿圆柱齿轮精锻工艺[J].锻压技术，2002,27(5):1-4.JIANG Xiongxin,WAN Pingrong,LIN Zhiping.Precision forging process of spur gear[J].Forging & Stamping Technology,2002,27(5):1-4.
[7] 蒋鹏，徐祥龙.齿类零件精密锻造技术[J].金属加工(热加工),2013,(19):16-20.JIANG Peng,XU Xianglong.Precision forging technology of tooth parts[J].Metal Working(Hot Working) ,2013,(19):16-20.
[8] 胡亚民，华林，赖周艺，等.汽车摩托车齿轮类零件的冷摆辗精密成形[J].中国机械工程，2006,17(S1):140-143.HU Yamin,HUA Lin,LAI Zhouyi,et al.The technology of cold precision orbital forming of various gears in automobile and autobicycle[J].China Mechanical Engineering,2006,17(S1):140-143.
[9] 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.YIN Haixing.Research on cold rotary rolling precision forming technology of bevel gear and development of CAD/CAPP system[D].Wuhan:Wuhan University of Technology,2002.
[10] 赵军华，莫江涛，成国发，等.直齿锥齿轮精锻技术现状和发展 [J].金属加工(热加工),2008,(17):14-17.ZHAO Junhua,MO Jiangtao,CHENG Guofa,et al.Current status and development of precision forging technology for straight bevel gear[J].Metal Working(Hot Working) ,2008,(17):14-17.
[11] ZHENG F,HUA L,HAN X H,et al.Linkage model and manufacturing process of shaping non-circular gears [J].Mechanism and Machine Theory,2016,96:192-212.
[12] 庄武豪.直齿非圆锥齿轮热锻成形规律与精度控制方法研究[D].武汉：武汉理工大学，2019.ZHUANG Wuhao.Research on hot forging process and accuracy control method of non-circular spur bevel gear[D].Wuhan:Wuhan University of Technology,2019.
[13] 陈泽中，林治平，连书勤.直齿圆柱齿轮镦挤精锻模拟[J].塑性工程学报，2000,7(1):55-59.CHEN Zezhong,LIN Zhiping,LIAN Shuqin.Simulation to upsetting extrusion precision foring of spur gear[J].Journal of Plastic Engineering,2000,7(1):55-59.
[14] 陈拂晓，姜开宇，杨永顺，等.直齿轮径向挤压过程变形力规律的数值模拟[J].中国机械工程，1998,9( 9):12-14.CHEN Fuxiao,JIANG Kaiyu,YANG Yongshun,et al.Numerical simulation of deformation force in spur gear radial extrusion process[J].China Mechanical Engineering,1998,9(9):12-14.
[15] CHITKARA N R,BHUTTA M A.Near net shape spline forging:An experimental investigation and a simple upper bound analysis [J].International Journal of Mechanical Sciences,1995,37(12):1247-1268.
[16] CHITKARA N R,BHUTTA M A.Near-net shape forging of spur gear forms:An analysis and some experiments[J].International Journal of Mechanical Sciences,1996,38(8-9):891-916.
[17] 吕季营.斜齿轮精密成形模具弹性行为分析与控制方法[D].武汉：武汉理工大学，2018.Lü Jiying.Analysis and control method of elastic behavior of helical gear precision forming die[D].Wuhan:Wuhan University of Technology,2018.
[18] 张治民，张宝红，仇明侠.直齿圆柱齿轮开放成形数值模拟[J].塑性工程学报，2006,13 (1):71-73.ZHANG Zhimin,ZHANG Baohong,CHOU Mingxia.Numerical simulation of open forming of spur gear[J].Journal of Plasticity Engineering,2006,13 (1):71-73.
[19] DENG X B,HUA L,HAN X H.Three-dimensional FE modelling simulation of cold rotary forging of spiral bevel gear [J].Ironmaking & Steelmaking,2011,38(2):101-111.
[20] FENG W,HUA L,HAN X H.Finite element analysis and simulation for cold precision forging of a helical gear[J].Journal of Central South University,2012,19(12):3369-3377.
[21] 董丽颖.直齿锥齿轮冷摆辗宏观变形与微观组织研究[D].武汉：武汉理工大学，2015.DONG Liying.Research on macroscopic deformation and microstructure of straight bevel gear with cold rotary forging[D].Wuhan:Wuhan University of Technology,2015.
[22] HAN X H,HUA L,ZHUANG W H,ZHANG X C.Process design and control in cold rotary forging of non-rotary gear parts[J].Journal of Materials Processing Technology,2014,214(11),2402-2416.
[23] 邓小宾.锥齿轮冷摆辗精密成形规律和工艺参数优化设计[D].武汉：武汉理工大学，2010.DENG Xiaobin.Optimization design of precision forming rules and process parameters of cold rotary rolling bevel gear[D].Wuhan:Wuhan University of Technology,2010.
[24] 吴舒婷.20CrMnTiH钢高温塑性变形行为与微观组织的研究[D].武汉：武汉理工大学，2015.WU Shuting.Research on plastic deformation behavior and microstructure of 20CrMnTiH steel at high temperature[D].Wuhan:Wuhan University of Technology,2015.
[25] 王明辉.直齿圆柱齿轮精密塑性成形工艺及关键设备研究[D].长春：吉林大学，2010.WANG Minghui.Research on precision plastic forming technology and key equipment of straight gear[D].Changchun:Jilin University,2010.
[26] KONDO K,OHGA K.Precision cold die forging of a ring gear by divided flow method[J].International Journal of Machine Tools and Manufacture,1995,35(8):1105-1113.
[27] 薛勇，张治民，王科.圆柱齿轮镦挤成形约束分流的数值模拟[J].锻压技术，2007,32(3):115-119.XUE Yong,ZHANG Zhimin,WANG Ke.Numerical simulation of constrained shunt in upset-extrusion forming of cylindrical gear[J].Forging & Stamping Technology,2007,32(3):115-119.
[28] CAI J,DEAN T A,HU Z M.Alternative die designs in net-shape forging of gears[J].Journal of Materials Processing Technology,2004,150(1-2):48-55.
[29] 俞德哲，王新云，金俊松，等.空心圆柱斜齿轮正挤压数值模拟研究[J].锻压技术，2013,38(2):147-150.YU Dezhe,WANG Xinyun,JIN Junsong,et al.Numerical simulation of forward extrusion of hollow cylindrical helical gear[J].Forging & Stamping Technology,2013,38(2):147-150.
[30] DENG X B,HUA L,HAN X H,et al.Numerical and experimental investigation of cold rotary forging of a 20CrMnTi alloy spur bevel gear [J].Materials & Design,2011,32(3):1376-1389.
[31] LI J,WANG G C,WU T.Numerical simulation and experimental study of slippage in gear rolling[J].Journal of Materials Processing Technology,2016,234:280-289.
[32] DONG L Y,LAN J,ZHUANG W H.Homogeneity of microstructure and Vickers hardness in cold closed-die forged spur-bevel gear of 20CrMnTi alloy [J].Journal of Central South University,2015,22(5):1595-1605.
[33] ZHUANG W H,DONG L Y.Effect of key factors on cold orbital forging of a spur bevel gear [J].Journal of Central South University,2016,23(2):277-285.
[34] 陆晓星.热精锻直齿锥齿轮模具设计及仿真 [D].济南：山东大学，2011.LU Xiaoxing.Die design and simulation of hot precision forging straight bevel gear [D].Jinan:Shandong University,2011.
[35] LIU J,CUI Z.Hot forging process design and parameters determination of magnesium alloy AZ31B spur bevel gear [J].Journal of Materials Processing Technology,2009,209(18-19):5871-5880.
[36] ZUO B,WANG B,LI Z,et al.Design of relief-cavity in closed-precision forging of gears [J].Journal of Central South University,2015,22(4):1287-1297.
[37] 许思佳.斜齿轮分流-挤压复合成形工艺与模具结构[D].武汉：武汉理工大学，2018.XU Sijia.Research on shunt-extrusion compound forming process and die structureof helical gears[D].Wuhan:Wuhan University of Technology,2018.
[38] 冯玮，徐富家.20CrMnTiH热压缩微观组织演变及动态再结晶模型[J].塑性工程学报，2014,21(3):78-84.FENG Wei,XU Fujia.Microstructure evolution and dynamic recrystallization model of 20CrMnTiH hot compression[J].Journal of Plasticity Engineering,2014,21(3):78-84.
[39] 秦飞.螺旋圆柱齿轮热精锻成形微观组织预测及演化规律研究[D].武汉：武汉理工大学，2017.QIN Fei.Research on microstructure prediction and evolution of spiral cylindrical gear formed by hot precision forging[D].Wuhan:Wuhan University of Technology,2017.
[40] LEE S R,LEE Y K,LEE C H,et al.Process modification of bevel gear forging using three-dimensional finite element analysis [J].Journal of Materials Processing Tech.,2001,113(1):59-63.
[41] SONG J H,IM Y T.Process design for closed-die forging of bevel gear by finite element analyses [J].Journal of Materials Processing Technology,2007,192-193:1-7.
[42] 金俊松.轿车齿轮闭式冷精锻近/净成形关键技术研究[D].武汉：华中科技大学，2009.JIN Junsong.Research on key technology of closed cold precision forging near/net forming of car gear[D].Wuhan:Huazhong University of Science and Technology,2009.
[43] 薛克敏，李晓冬，李萍，等.圆柱斜齿轮浮动凹模冷挤压成形仿真与实验研究[J].中国机械工程，2012,23(4):464-468.XUE Kemin,LI Xiaodong,LI Ping,et al.Simulation and experimental study on cold extrusion of cylindrical helical gear with floating die[J].China Mechanical Engineering,2012,23(4):464-468.
[44] 刘丹，刘华，王伟钦，等.直齿圆柱齿轮冷挤压可控运动凹模成形工艺[J].锻压技术，2016,41(9):84-87.LIU Dan,LIU Hua,WANG Weiqin,et al.Cold extrusion and controlled motion die forming technology of spur gear[J].Forging & Stamping Technology,2016,41(9):84-87.
[45] CHOI J C,CHOI Y.Precision forging of spur gears with inside relief[J].International Journal of Machine Tools and Manufacture,1999,39(10):1575-1588.
[46] 寇淑清，杨慎华，黄良驹，等.用约束分流法冷锻成形高精度直齿圆柱齿轮[J].吉林工业大学自然科学学报，2000,30(2):19-23.KOU Shuqing,YANG Shenhua,HUANG Liangju,et al.High precision straight gear was formed by cold forging with restrained shunt method[J].Journal of Natural Science,Jilin University of Technology,2000,30(2):19-23.
[47] WANG G C,ZHAO G Q,XIA S S,et al.Numerical and experimental study on new cold precision forging technique of spur gears[J].Transactions of Nonferrous Metals Society of China,2003,13(4):798-802.
[48] FENG W,HUA L.Multi-objective optimisation of process parameters for the helical gear precision forging by using Taguchi method,Journal of Mechanical Science and Technology,2011,25(6):1519-1527.
[49] HAN X H,HUA L.3D FE modelling of contact pressure response in cold rotary forging [J].Tribology International,2013,57:115-123.
[50] HUA L,HAN X H.3D FE modeling simulation of cold rotary forging of a cylinder workpiece [J].Materials & Design,2009,30(6):2133-2142.
[51] HAN X H,HUA L.Effect of size of the cylindrical workpiece on the cold rotary-forging process[J].Materials & Design,2009,30(8):2802-12.
[52] ZHUANG W H,HUA L,HAN X H,et al.Distribution of microstructure and vickers hardness in spur bevel gear formed by cold rotary forging [J].Advances in Mechanical Engineering,2014,6:809276.
[53] HAN X H,DONG L Y,HUA L,et al.Microstructure and texture evolution in cold rotary forging of spur bevel gears of 20crmnti alloy steel [J].Journal of Materials Engineering and Performance,2016,25(3):1182-1190.
[54] 李心蕊.从动螺旋锥齿轮精密锻造成形及其数值模拟研究[D].济南：山东大学，2021.LI Xinrui.Research on precision forging forming of driven spiral bevel gear and its numerical simulation[D].Jinan :Shandong University,2021.
[55] 丁瑞良.汽车后桥从动螺旋伞齿轮精密锻造工艺的研究[D].长春：吉林大学，2016.DING Ruiliang.Research on precision forging technology of automobile rear axle driven helical bevel gear[D].Changchun:Jilin University,2016.
[56] 高波.双辊摆辗螺旋锥齿轮成形工艺研究[D].武汉：武汉理工大学，2018.GAO Bo.Research on forming technology of spiral bevel gear with double roll rotary rolling[D].Wuhan:Wuhan University of Technology,2018.
[57] 韩星会，华林，郑方焱，等.多自由度包络成形装备精度和稳定性控制方法：中国[P].CN115270511A,2022-11-01.HAN Xinghui,HUA Lin,ZHENG Fangyan,et al.Precision and stability control method of multi-degree-of-freedom envelope forming equipment:China[P].CN115270511A,2022-11-01.
[58] 韩星会，华林，郑方焱，等.多自由度包络成形装备运动-刚度协同优化设计方法：中国[P].CN115422672A,2022-12-02.HAN Xinghui,HUA Lin,ZHENG Fangyan,et al.Precision and stability control method of multi-degree-of-freedom envelope forming equipment:China[P].CN115422672A,2022-12-02.
[59] 陈仲宝.航空面齿轮冷摆辗成形工艺设计方法与成形规律研究[D].武汉：武汉理工大学，2022.CHEN Zhongbao.Research on design method and forming rule of cold swing forging process for aircraft face gear[D].Wuhan:Wuhan University of Technology,2022.
[60] 华林，郑方焱.非圆齿轮研究现状及展望[J].北京工业大学学报，2018,44(7):969-978.HUA Lin,ZHENG Fangyan.Research status and prospect of non-circular gear[J].Journal of Beijing University of Technology,2018,44(7):969-978.
[61] ZHUANG W H,HUA L,HAN X H ,et al.Design and hot forging manufacturing of non-circular spur bevel gear[J].International Journal of Mechanical Sciences,2017,133:129-146.
[62] HAN X H,HUA L,ZHUANG W H,et al.Process design and control in cold rotary forging of non-rotary gear parts[J].Journal of Materials Processing Technology,2014,214(11):2402-2416.
基本信息:
DOI：
中图分类号:TH132.41
引用信息:
[1]华林,冯玮,韩星会等.齿轮精密塑性成形理论技术装备研究与应用[J].塑性工程学报,2024,31(04):56-73.
基金信息:
国家自然科学基金资助项目(52275369); 高等学校学科创新引智计划项目(B17034)