Computer Simulation And Optimization Of Process Parameters In Fineblanking Of The Fine-pitch Gear Form

The traditional processing of the gear wheel parts needed to carry through the working procedure of blanking punching, hinging center hole, hobbing, trimming and so on, and the machining time was long. As an advanced precise plastic forming technology, fine blanking technology can obtain the parts with high-precision size, bright shear plane and certain three-dimensional shape in one blanking process. As the development of the fine blanking, more and more gear wheel parts adopted the method of fine blanking forming processing. Because the gear wheel parts are thick, the fine blanking for gear wheel parts, especially for the small modulus gears is difficult. At present, there are a large number of problems existed in the fine blanking of gear wheel parts, on the one hand, it is easy to tear in the addendum of machined material because of the influence of parts profile. On the other hand, in the addendum, punch bears tremendous pressure, resulting in the damage of die too early.How to predict the possible defects in the processing of fine blanking and acquire the reasonable processing parameters is becoming the important link of developing fine blanking technology. Presently, in the practical production process, the fine blanking of gear wheel parts often draws upon traditional methods such as experience and processing experiment and so on to achieve. Due to the limitations of traditional research methods, design and production cycle are long, which lead to the low productivity.On the base of synthesis consult and digest absorb a great deal of overseas and domestic literature information, investigate the forming process in the fineblanking of fine-pitch gear form. In this paper, the numerical analog simulation of fine blanking micron gears is studied by using finite element software system Deform3D on the basis of analysis of fine blanking mechanism. The effect of blanking Clearance, V-ring dimension, V-ring force, Counter force, Radius of die edge on the blanking process is discussed. From this we has got the relationship between above parameter and clean cut height of the shear surface, The flow behavior of metal in deformation zone and change law of stress and strain under different process parameters in the process of fine blanking is revealed. Meanwhile, introduce the ductile fracture criterion of Cockcroft &Latham to predict the time and site of appearance and growth of the crack, and discuss the causes of the defects (tearing slits, crack and so on) in the course of forming. At last the prediction of cutting force of fine blanking has got through use the finite element analysis.To validate and supplement the finite element analysis results ,The mechanics of the fine blanking has been studied in the way of experiment, The research results show that, through the motion simulation, experiments has been carried out that the results is consistent with the finite element simulation, The research result is beneficial for the optimal design of the fine blanking process and the die, design efficiency enhanced, design cost reduced effectively and the and efficacy improved, and it has universal guide and reference means to the continual application of investigation and generalization.