摘 要

橡胶履带D86-2型铁齿是一种典型的复杂阶梯状分型面零件，作为一种传动件，在橡胶履带使用中承受弯曲力、剪切力、扭转力和支撑力等，起动力传递、导向及横向支撑作用。目前采用的工艺是自由锻制坯，对原材料进行初始体积分配，将坯料两端拔长，制坯成中间粗、两端逐渐变细的形状。本文尝试用辊锻工艺制造坯料。辊锻是使计算得到目标坯料平稳通过一对装有锻模的旋转的辊子，并使金属在辊子旋转中变形。与其它一般的传统加工方法相比，锻造加工的生产率为最高；而且金属材料通过塑性变形过程后，容易消除其内部缺陷，得到均匀、细小的微观组织。

本文的目的是在有限元模拟软件DEFORM-3D环境下，实现了对铁齿辊锻制坯工艺的模拟及优化。研究的主要内容是设计一种坯料代替过去传统坯料，对制坯辊锻模具进行设计，以及通过DEFORM-3D模拟后得到的应变应力、金属流动特性，不断修改工艺参数并反复模拟，实现了对辊锻工艺的优化。

本文的研究成果是设计出一种双鼓型坯料以及其辊锻模具，同时进行了数值模拟，并发现随着坯料初始温度和摩擦因子的提高，锻件轴向伸长量和应变会相应提高，从而得到合适的温度和摩擦因子。研究结果表明辊锻加工出的锻件形状、尺寸稳定性较好。

关键词：轴类锻件；辊锻制坯；数值模拟

Abstract

Rubber track iron teeth D86-2 is a typical complex stepped into surface parts, as a kind of transmission, in the use of rubber track subjected to bending force, shear, torsion force and support force etc., power transfer, the guidance and the transverse supporting role. At present, the process is free forging blank, the initial volume distribution of raw materials, the billet at both ends of the length of the billet into the middle coarse, both ends of the gradual tapering shape. In this paper, we try to make blank with roll forging process. Roll forging is the calculated target blank smoothly through the forging die with a pair of rotating rollers, and makes the metal roller rotary deformation. Compared with other conventional processing methods, the productivity of forging process is the highest, and the metal material is easy to eliminate its internal defects after plastic deformation process, and it can get uniform and fine microstructure.

The purpose of this paper is to realize the simulation and optimization of the process of forging blank of the gear with the finite element simulation software DEFORM-3D. The main content of the study is designed to a blank instead of the past traditional blank, of billet of roll forging die design, and force, the character of the metal flow through the DEFORM-3D simulation and get the strain stress and continue to modify the process parameters and repeated simulation, to realize the optimization of roll forging technology.

The results of this study is to design a double drum type blank and the roll forging die, and carry out numerical simulation. And found that with the increase of initial temperature of billet and the friction coefficient and axial elongation of the forging and strain will increase accordingly, so as to obtain the appropriate temperature and friction coefficient. The results show that the shape and the dimension stability of the roll forging are better.

Key Words：Axial forgings；Roll forging billet；numerical simulation

目录

摘要 I

Abstract II

目录 III

第1章绪论 1

1.1 引言 1

1.2 国外发展现状分析 2

1.3 国内发展现状分析 3

1.4 辊锻制坯工艺基本内容 4

1.5 辊锻制坯工艺目标及方法 4

1.6 本章小结 4

第2章铁齿辊锻制坯工艺研究 6

2.1 引言 6

2.2 计算原始棒料尺寸 6

2.2.1 计算辊锻毛坯 6

2.2.2 辊锻件的尺寸研究 11

2.3 辊锻型槽系的选择 12

2.4 辊锻道次的确定 13

2.5 辊锻毛坯各道截面尺寸计算 13

2.6 计算型槽尺寸 15

2.6.1 椭圆型槽 15

2.6.2 圆形型槽 16

2.7设计型槽纵向尺寸 16

2.7.1 确定辊锻毛坯过渡区段长度尺寸 17

2.7.2 型槽纵向长度尺寸的确定 17

2.8 本章小结 18

第3章铁齿辊锻制坯工艺的有限元模拟 19

3.1 引言 19

3.2 模拟平台 19

3.2.1 DEFORM-3D简介 19

3.2.2 DEFORM-3D主要功能 20

3.3 刚塑性有限元法的概述 20

3.4 PRO/E环境下对铁齿辊锻制坯模具造型 21

3.4.1 创建三维模型 21

3.4.2 模具装配 22

3.5 铁齿辊锻制坯有限元模拟 23

3.6 本章小结 25

第4章铁齿辊锻制坯工艺有限元分析及优化 27

4.1 引言 27

4.2 温度对坯料伸长量和应变的影响 27

4.3 摩擦因子对应变和坯料轴向伸长量的影响 29

4.4 本章小结 31

第5章结论与展望 32

5.1 结论 32

5.2 展望 32

参考文献 33

致谢 34

第1章 绪论

1.1 引言

在现代化机械制造中，常常会用到一种旋转型零件即轴类零件^[1]。此类零件多为圆柱形，且沿轴向方向的截面直径会大不相同，又称为所谓的阶梯轴零件。在大部分机器运转过程中，主要起到承担重要载荷以及传递动力力矩的作用，其重要性不言而喻。常使用锻造工艺加工，在这种情况下，既可以减少机加工量，又可以提高效率。