齿轮锻造工艺设计说明书Gear forging process design manual.docx

齿轮锻造工艺设计说明书Gear forging process design manual.docx

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齿轮锻造工艺设计说明书Gearforgingprocessdesignmanual

齿轮锻造工艺设计说明书（Gearforgingprocessdesignmanual）

Gearforgingprocessdesignmanual

Abstract:

thepurposeofforgingblankmolding,andcontrolofitsinternalorganizationalperformancereachedthedesiredgeometry,sizeandqualityofforgings,steelandnon-ferrousmetalandalloyhasthemostplasticindifferentdegrees,canbeplasticmoldingprocessincoldorhot.Theforgingofgearsadoptsthefreeforgingprocess.Thispapermainlyintroducesthefreeforgingprocessofgears.Freeforgingistheuseofpressureorimpactforceisthemetalbetweentheupperandlowerirondeformationbetweenplasticdeformation,soastoobtaintheshapeandsizeoftherequiredmethod.Thedeterminationoffreeforgingbecomesthekeytofreeforging.Thisarticlefocusesontheprocessoffreeforgingofgears.

Keywords:

freeforging,gearprocessing,plasticdeformation,processflow.

Catalog

I.introduction............................................................One

Two.Overalldesignplan................................................One

Three.Specificdesignmethodsandsteps....................................Three

3.1drawtheforgingdrawing.............................................Three

3.2determinethedeformationprocess..........................................Three

3.2.1upsetting.............................................Three

3.2.2punching.............................................Four

3.2.3reaming.............................................Four

3.2.4trimmingforgings.......................................Four

Three

3calculatebilletqualityandsize.................................Four

3.4selectionofequipmentandspecifications.......................................Five

Four.Processflow（processcard）.......................................Six

Five.Conclusion............................................................Seven

Six.Thanks............................................................Seven

Seven.References......................................................Eight

Manufacturabilityanalysisofforgingstructure

forgingdrawing

Parameterselection

Determinationofmachiningallowanceanddeterminationoftolerances

Determinebilletquality

Determinationprocedure

Selectionofforgingequipment

Determinationofheatingtemperatureandheatingtime

Postforgingheattreatment

The1.partdrawingprocess,attachedtotheinstructions,theA4papertoprintorfreehand.

2.frontcoverformat:

1.designspecificationsmustbewritten,withA4paper,cover,catalogue,textandreferences.

Advanceddesignandmanufacturingintegratedexperiment

XXpartXXprocessdesign

class

Fullname

I.Introduction

Thepurposeofforgingistomaketheblankformingandtocontrolitsinternalstructuretoachievetherequiredgeometry,sizeandqualityoftheforgings.Thebasicprocessofforgingisfreeforging,dieforging,sheetmetalstamping,inwhichfreeforginganddieforgingarethermoplasticforming,andsheetstampingiscoldplasticforming,thebasicprincipleofbothisthesame.

Theproportionofforgedpartsshowsthestatusofacountry'sproductionlevel,productivity,materialutilization,productioncostsandproductqualityininternationalcompetition.BeforethefoundingofnewChina,forgingwasbasicallyacontinuationofhandicraftworkshops,withlowproductionefficiencyandgreatlaborintensity.However,afterthereformandopeningup,China'sforgingtechnologyhasbeenrapiddevelopment,whichledtotheautomotiveindustry,suchasleapsandbounds.ButweshouldalsoclearlyseethatourforgingtechnologylevelandEuropeanandAmericandevelopedcountriesstillhaveacertaingap,whichmakesusmoreeffortstodevelopnewtechnologies,catchupwiththeinternationaladvancedlevel.

Gearisalargenumberofpartsusedinmodernindustry.Thispaperdiscussesthefreeforgingproductionofgears.Freeforgingcanbecarriedoutalotofprocesses,canbedividedintobasicprocesses,auxiliaryprocesses,andfinishingprocessthreemajorcategories.Itsbasicprocessistomakethemetalproduceacertaindegreeofplasticdeformationinordertoachievethedesiredshapeandsizeoftheprocess,suchasupsetting,drawing,punching,bending,cutting,twistinganddislocationandotherprocesses.

Two,theoveralldesign

1.drawtheforgingdrawing

Accordingtothebasicdrawingofpartsdrawing,combinedwiththecharacteristicsoffreeforging,theresidualparts,forgingsallowanceandforgingtolerancesaredrawn.

2.calculatebilletqualityandsize

（1）calculationofbilletquality;

Accordingtotheshapeandsizeofforging,forgingqualitycanbecalculatedfirst,thenconsidertheoxidationlossduringheating,lossofcorematerialandflushcuttingheadpunching,qualityfirstforthecalculationofblankforgings,thecalculationformulaisasfollows

Mbillet,=mforging,+mfiring,+mhead,+mcore

（2）determinationofblanksize;

Theleathersizearecorrelatedwiththefirstbasicprocess,becausethegeariscakeorhollowforgings,withupsettingforgingprocess,inordertoavoidupsettingbending,shouldmaketheblankheighthofnotmorethan2.5timesthediameterofD,whichbasesontheratioofheighttodiameterlessthan2.5h/D.Inordertofacilitateoperationduringcutting,theblankheighthshouldbelessthan2.5D,thatis,theratioofheighttodiametershouldbegreaterthan1.25

Diameterofroundmaterial.

3.choosetheforgingprocess

Gearforging,accordingtoitslateralsizegreaterthanorneartheheightofthecharacteristics,mainlytoupsettingthemain,whentheforginghasaconvexshoulder,accordingtothesizeoftheshoulderpadselectionring,upsettingorpartialupsetting.Iftheforgingholeneedstoberushedout,itneedstobepunched.

4.selectedforgingequipment

Theselectionofforgingequipmentisbasedonthematerial,sizeandqualityoftheforgings,aswellastheexistingequipmentconditionsoftheworkshop.Iftheequipmenttonnageistoosmall,theforginginternalisnotthorough,theproductivityislow,buttheequipmentandpowerwaste,andtheoperationisinconvenientandunsafe,usuallybyempiricalanalogyorlook-uptablemethod.

（1）empiricalanalogy

Accordingtotheempiricalformulaofhammertonnage:

TheupsettingforginghammertonnageG=（0.002-0.0003）KS（kg）

（2）look-uptableselection

Forlowcarbonsteel,mediumcarbonsteelandordinarylowalloysteel,thefreeforgingcanbecheckedbytheselectedtonnage.

5.determinetheforgingtemperatureandspecifications

（1）determinetherangeofforgingtemperature

Theforgingtemperaturerangeofallkindsofalloysteelcanbefoundfromthetable.Thebasicprincipleistoensurethatthesteelhasgoodplasticityandlowdeformationresistanceintherangeofforgingtemperature,andcanforgehighqualityforgings,

Andawiderangeofforgingtemperatureandlessheatingtimes,aswellashigherproductivity.

（2）determinetherangeofheatingandcooling

Forthecarbonstructuralsteelwithagoodthermalconductivityandadiameteroflessthan150~200mm,asectionofheatingcodeshallbeadopted,andthefurnaceshallbecontrolledatatemperatureof1300~1350c..Whenthebilletisheatedtotheinitialforgingtemperature,itisimmediatelybakedandforged.

（3）determinationofcoolingmethodsandspecifications;

Chooseaircooling,pitcoolingorfurnacecoolingasrequired.Smallandmediumcarbonsteelandlowalloysteelareforgedbyaircoolingmethodwithfastercoolingrate.Carbontoolsteel,alloytoolsteelandbearingsteel,forged,aircooled,blown,orsprayedquicklyto200degrees,thenputtheforgingsintoapitorcooledinafurnace.

Three,thespecificdesignmethodsandsteps

1.drawpartsdrawing

Thematerialofthispartis40Cr,andtheproductionissmallinquantity.Thegearblanksareforgedbyfreeforging.

Thegearonthecircumferenceofthesmallgrooveshoulderand8x30mmdiameterholepart,thefreeforgingmethodisverydifficulttoformtheseparts,consideringthefeasibilityandeconomyoftechnology,anddecidednotforged,andtheadditionalblockshapetosimplifytheforging,forging.Afterforgingthegearblank,itcanbefurtherprocessedandfinallyformed.

Accordingtothedimensionofthepartsdrawing,theheightandthediameterofthepartslistedinthecomparisontable,theallowanceandtolerancesforthemachiningofthegearforgingscanbefoundout.D=289,h=52,machiningallowanceandtolerancecheckforhorizontalforgingforgingheightdirectiona=10+4,b=9+3,c=13+5holebilateral,andpresschecktolerancescanbedrawnnumericalShoulderGearForgingdrawing.

Forgingdrawingisgivenseparately.

2.determinethedeformationprocess

Convexshouldershapedgearforgingsbelongstothehollowpart,accordingtotheshapeandsizeofforgings,forgingintheforginghammer,andthemaindeformationprocessforupsettingandpunching,punchreamingprocess,theauxiliarycushionringupsettingformingisdeterminedaccordingtotheforgingoftheshouldershape.

Atpresent,thesekindsofshortswordsgenerallyusepartialupsetting,whileupsettingformingissuitableforshoulderforgingswithsmalldiameterandheight.Becausethegeardiameterislarger,sowedecidetousethepunchreaming,butconsideringthepunchingmetalwillflowalongtheradialhole,andalongtheheightdirectionoftheshoulderpullingshrinkagephenomenon,sothatthecushionringupsettingafterthediametersizeshouldbesmallerthanthediameteroftheforging,andshoulderheightshouldbegreaterthantheforgingshoulder.

（1）upsetting

Sincetheforgingsaresinglesided,thepadringshallbeupset,a