锻压技术

汽车变速箱空心齿套锻造工艺仿真与实验

英文标题：Simulation and experiment on forging process for hollow gear sleeve of automotive gearbox

作者：柴慧理

分类号：TG376.3

出版年,卷(期):页码：2025,50(7):36-43

摘要：

以汽车变速箱空心齿套为研究对象，针对当前工艺复杂、材料加工余量大、产品质量差、生产效率不理想等问题，进行了多工位冷锻工艺研究。完成了空心齿套的冷锻方案设计，建立了对应的锻造仿真模型，并研究了实际锻材的本构模型；通过Deform-3D完成了工艺仿真，分析了齿套各阶段的成形过程、成形结果及断面流线情况，对工艺的可行性进行了评估；结合压缩实验与数值模拟确定了材料断裂损伤临界值，建立了精确的断裂预测模型，并据此评估了齿套各阶段的断裂风险；完成了齿套的锻造试验，试验结果与仿真预测结果高度吻合，齿形、薄壁等成形饱满，孔壁光滑，不存在缺料、裂纹、刮伤等缺陷，验证了工艺的可靠性。

For the hollow gear sleeve of automotive gearbox, a multi-station cold forging process was studied to address the current problems of complex process, large material processing allowance, poor product quality and unsatisfactory production efficiency, and the cold forging scheme of hollow gear sleeve was designed. Then, the corresponding forging simulation model was established. Meanwhile, the constitutive model of the actual forging material was studied. Furthermore, the process simulation was completed by Deform-3D, and the forming process, forming result and flow lines in cross-section of gear sleeve at each stage were analyzed to evaluate the feasibility of the process. In addition, the critical fracture damage value of material was determined by combining compression experiment with numerical simulation, and an accurate fracture prediction model was established. Based on this, the fracture risk of gear sleeve at each stage was evaluated, and the forging test of gear sleeve was completed. The research results show that the test results are highly consistent with the simulation prediction results. The tooth shape and thin wall are fully formed, the hole wall is smooth, and there are no defects such as missing materials, cracks, scratches, etc., which verifies the reliability of the process.

基金项目：

山西省基础研究计划（自由探索类）；2022年度青年项目(202203021222327)

作者简介：柴慧理（1970-），男，学士，副教授 E-mail：92K1Q@aliyun.com

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