Research On Process Optimization And Mold Of Closed-extruding Fine Blanking Spur Gear

The Traditional V-ring fine-blanking is used to form parts of precision profile withhigh efficiency, low cost and good quality advantages. However, the thickness and plasticof parts are demanded grindingly for this process, The closed-extruding fine blankingtechnology is suitable for forming the parts of high thickness or poor plasticity, itbroadens requirements of fine blanking technology for thickness and plasticity.Firstly, the force situation of material in deformation zone is analyzed forclosed-extruding fine blanking process, the influence factor of hydrostatic stress is received;moreover the force loading status of closed-extruding fine blanking die is analyzed, andthe Main failure form is obtained.That closed-extruding fine blanking spur gear is simulation analyzed byDEFORM-3D finite element software. According Simple contrast experiment, the processparameters impact maximum wearing depth of main-die for single blanking and theproportion of smooth surface, they are clearance between punch and die, fillet radius of die,inclination angle of primary and secondary concave cavity and counter force.While the maximum wearing depth of main-die for single blanking and the proportionof smooth surface is used as an indicator, The orthogonal test of four factor atfour factors at four different levels is set, the optimal parameter combination is obtained bycomprehensive evaluation method; the degree of influence of process parameters on theseindicators is received by extreme difference analysis.The mold structure is optimized by setting Shunt decompression chamber and doublecombinational die structure, improving lubrication condition, as the result, the mold forceis reduced and the die life is improved.A large number of experiments is carried out on the basis of finite element simulation.According the mesh experiment, the material flow characteristics of closed-extruding fineblanking gear is researched, it reveals the forming mechanism and explains the reasons thatthe top surface of tooth is easy to be torn;The influence of the counter force, the outer-ringfill rate and Shunt decompression chamber on proportion of smooth surface,Parts stepping angle and die force are studied; The experiments of lubrication is designedto study the effects of mold force; different materials is chosen for closed extruding fineblanking, the influence of plastic materials to the quality of the gear is analyzed. The optimization of process parameters and the mold structure for Closed-extrudingfine blanking gear can lay the foundation for it coming into the market andindustrialization.