Physical Simulation And Numerical Simulation Of Stamping-extrusion And Bulge-extrusion Combining Forming For Spur Gear

Generally speaking, there are three substance supports the civilization of human being, material, energy sources and information. Actually, manufacture is the main body of the industrial, it can provide tool of production, means of subsistence, means of science and technology, equipment of national defense that entire progressive rely on manufacture, and manufacture is one of modern power supply.Advanced manufacturing technology (ATM) is a floorboard; it is multi-hierarchical technique group, go by the name of face to 21 century technique of manufacture. It is an achievement that manufacture ever absorbs machine, electron information, energy sources and modern system management, over all prices of integrate apply to product design, manufacture detection management, marketing, application, service and reclaimed manufacture. So that come true high grade, high efficiency, low cost, cleanliness and agility manufacture, enhance adaptive faculty and competitive ability to dynamic multivariate of product markets. ATM is a multi-subject system, it means exceed traditional technique of Manufacture Corporation and department, even limit of nationality, including from market demanded, environmental requirement, innovation design, process engineering to procedure, organize and monitoring market information engineering system.For the plastic forming technology have many merits, such as high production, good quality and economization. It has become an important develop orientation of the advanced manufacture technology. Research theprocess of metal plastic forming consists of numerical simulation and physical simulation. Numerical simulation becomes broad application in recent years, because that it can shorten the time of mould design and support develops of borderline product effectively. But for the piece with large invested funds need simulation experiment, because that it will affect normal production and cycle length, cost high if experiment on the object directly. Numerical simulation can not carry an exact result because of simplify model and can not observe internal rule of deformation; it can be make up by physical simulation. Now, it is a trend to develop all of them.Gear is one of pieces used widely in aviation, spaceflight, automobile and motorcycle etc. Precise plastic forming technique for manufacturing gear not only save materials and energy, reduce the lost and improve the efficiency, but also make the gear produced by this technique be of good streamline, reasonable and ideal distribution of fiber structure, which enhance flexural strength of tooth and contact fatigue strength on the tooth face, improve wear ability improved and prolong operating life. So it is necessary to study gear's precise plastic forming. Precise forming gear is a kind of new technology which is no cutting processing. The main aim of precise forming gear is to produce complete tooth shape which do not need cutting processing or leave few allowance for finish. At present, research of precision forging spur gear just in laboratory investigation, the main work is on classical theoretical analysis (consist of slip line method, principal stress method, method of upper bounding, finite element method, etc) and experimental study.According to my tutor professor Song Yuquan's idea"The preparation of colour layer argil plasticine sample"prepared sample for experiment. And rely on my tutor's patent for invention"An adjustable hydraulic press with upside action and low action"does numerical simulation and physical simulation ofstamping-extrusion and bulge-extrusion combing forming for spur gear. The aspect of numerical simulation, the parameters of spur gear chosen in this thesis are module m=2,number of teeth z=20, angle of pressureα=20°, displacement coefficient x=0, technological plan was developed based on precise plastic forming technique, being on"Physical simulation and numerical simulation of stamping-extrusion and bulge-extrusion combining forming for spur gear". The die with up and down well rounded forcer for stamping-extrusion and bulge-extrusion combining forming were designed. Spur gear was modelled tri-dimensionally using parameters. Triaxiality elastic-plastic finite element modelling of stamping-extrusion and bulge-extrusion combining forming were established using software DEFORM. Adopt three different kinds of method to research gear forming, upset forming, stamping-extrusion and bulge-extrusion forming, post forming of stamping-extrusion and bulge-extrusion. The thesis obtained the distributions of stress-strain and temperature field, load-time (distance of run) curve, the distribution of contact force during stamping-extruding and bulge-extruding combining forming and investigated flow law of metal, which provided the theoretical basis of designing and optimizing technological parameters and die structure. Comparative study from three kinds of method, it concludes that the stress of stamping-extrusion and bulge-extrusion forming smaller then other methods, gear easy to full.Using argil plasticine as modelling material is easy to get, also its additive is little, and every time the coherence of the experimental material is good, so it can get over the disadvantage of the commercial plasticine that always change with process of the production. Plasticine each has different colour, and needn't accede to dye. So that can be sure that material is coherence better .Using different colour plasticine is easy to observe the distortion of plasticine. If the glutinosity of the argil plasticine is good, thendifferent parts of the slop can felt into together without superfluity glutinosity, that can be satisfied the require of the modelling experiment very well. Using the way delaminate colour clay sandwich plasticine, namely using different plasticine to make billet by the way of subsection and delimitation. For the parts need to review, when use different plasticine to make delimitation billet, we can make the other parts with one same colour. In the section of the sandwich plasticine, we can observe the flow circs of the material in radial and the status of the central material, conquering over the disadvantage of tradition girding way and is fit the study of this experiment. Design and make the installation of simulation experiment similar with an adjustable hydraulic press with upside action and low action, it can be available to simulate the process of stamping-extrusion and bulge-extrusion forming, also design and make layer billet.This kind of physical modelling experiment has been proved by stamping-extrusion and bulge-extrusion forming. Colour clay sandwich plasticine been delaminated in local can reappearing the movement of the material very well. It sets a base for it been used in more complex plastic forming latter.The result of physical simulation corresponding with the result of numerical simulation, full proofs the correctness of numerical simulation. The paper proved the probability and superiority of the innovative ideal about the stamping-extrusion and bulge-extrusion forming and will provide useful guidance for its development of industrialization.