齿轮轴向滚轧成形建模与轮齿完整性研究

doi:10.3901/JME.2018.06.133

机械工程学报 ›› 2018, Vol. 54 ›› Issue (6): 133-145.doi: 10.3901/JME.2018.06.133

齿轮轴向滚轧成形建模与轮齿完整性研究

马自勇¹, 罗远新^1,2, 王勇勤¹, 王宇¹

1. 重庆大学机械工程学院重庆 400044;
2. 重庆大学机械传动国家重点实验室重庆 400044

收稿日期:2017-10-01 修回日期:2017-12-08 出版日期:2018-03-20 发布日期:2018-03-20
通讯作者: 罗远新(通信作者),男,1981年出生,博士,副教授。主要研究方向为塑性成形工艺与装备。E-mail:yxluo@cqu.edu.cn
作者简介:马自勇,男,1987年出生,博士研究生。主要研究方向为齿轮滚轧成形。E-mail:zyma_sc@cqu.edu.cn;王勇勤,男,1961年出生,教授,博士研究生导师。主要研究方向为重型机械设备设计及工艺。E-mail:wyq@cqu.edu.cn
基金资助:
国家自然科学基金（51775062）和机械传动国家重点实验室特色研究（SKLMT-ZZKT-2015T01）资助项目。

Integrity and Modeling of Gear Tooth Forming in the Roll-forming of Gear with Axial Infeed

MA Ziyong¹, LUO Yuanxin^1,2, WANG Yongqin¹, WANG Yu¹

1. College of Mechanical Engineering, Chongqing University, Chongqing 400044;
2. The State Key Laboratory of Mechanical Transmission, Chongqing University, Chongqing 400044

Received:2017-10-01 Revised:2017-12-08 Online:2018-03-20 Published:2018-03-20

摘要/Abstract

摘要： 齿轮滚轧成形的轮齿完整性对轧轮齿根应力和寿命有着重要影响。为了揭示齿轮轴向滚轧成形齿高的增长规律，便于设计轧轮以及提高轧轮寿命，依据平面啮合理论及轴向滚轧工艺特点，推导出成形件的齿廓方程式；基于坐标变换法及齿轮轴向滚轧渐进成形特征，求得任意时刻轧轮半齿在齿坯截面上的包络面积；根据体积守恒，建立任意时刻齿轮轴向滚轧成形件的齿高估算模型，并据此得到轧轮精整段齿全高计算方程式。以模数为1.75 mm，压力角为20°，齿数为46的直齿轮滚轧为例，利用有限元和滚轧试验对所提出的模型与轮齿完整性进行分析。结果表明：齿高估算模型的理论值与试验值最大相对误差为4.97%；由齿全高计算模型设计的轧轮能保证轮齿完整性，避免成形齿顶出现“完全光顶”现象，防止兔耳缺陷埋入齿顶，影响成形齿的性能；同时，降低轧轮齿根应力32.89%。本研究为解决轧轮齿全高精确计算提供了理论基础。

关键词: 齿高估算模型, 齿轮滚轧成形, 啮合理论, 验证分析, 轧轮齿全高

Abstract: In the gear roll-forming process, extremely high stresses on the teeth of the rolling tools will appear when the rolling teeth are full filled with material. This will reduce the lifetime of the rolling tools. To understand the forming process and design the rolling tools as well as improve the lifetime of the rolling tools, it's necessary to model the tooth height estimation in the roll-forming of gear with axial infeed. The tooth profile equations are firstly derived based on the meshing theory. Considering its forming characteristics, the formula of envelope area evolution is obtained by the coordinate transformation method. The height estimation model of the formed teeth is then established with the assumption of volume conservation in the roll-forming process, and the equation for calculating the tooth depth on the correction section of rolling tools is also obtained. The roll-forming of spur gear with 46-teeth, module of 1.75 mm and pressure angle of 20° is taken as an example, and the proposed model and equation are verified by the finite element method and experiments. The compared results show that the maximum error between theoretical and experimental value is about 4.97%, and the rolling tools designed by the proposed tooth depth equation can ensure integrity of formed teeth, and avoid the forming of tip barreling and the folding defect which affect the performance of the formed teeth. Moreover, the root stress of rolling tools is reduced by 32.89%. This study will provide the theoretical foundation for calculating the tooth depth of rolling tools accurately.

Key words: gear roll-forming, meshing theory, tooth depth of rolling tools, tooth height estimation model, verification analysis

中图分类号:

TG335

马自勇, 罗远新, 王勇勤, 王宇. 齿轮轴向滚轧成形建模与轮齿完整性研究[J]. 机械工程学报, 2018, 54(6): 133-145.

MA Ziyong, LUO Yuanxin, WANG Yongqin, WANG Yu. Integrity and Modeling of Gear Tooth Forming in the Roll-forming of Gear with Axial Infeed[J]. Journal of Mechanical Engineering, 2018, 54(6): 133-145.

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齿轮轴向滚轧成形建模与轮齿完整性研究

Integrity and Modeling of Gear Tooth Forming in the Roll-forming of Gear with Axial Infeed

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