Analysis And Numerical Simulation Of The Forming Process Of Gear Sleeve Parts

Gear transmission system is the core component of many electromechanical products,and the quality of each component of the gear transmission system will directly affect the operation of gear rotation device and the whole mechanical products.Gear sleeve is a high strength,complex shape parts,which works in a poor conditions and a greater load pressure.Gear sleeve parts Warm-cold composite forming process compared to the traditional chip processing technology can reduce costs and improve product quality.This paper systematically analyzes the composite forming characteristics of the gear bushings,focuses on the forming process of the parts and the wear of the molds.In view of the friction lubrication of gear bushings,we research a new type of lubricant.The contents of this paper are as follows:(1)Study on the forming process of Gear sleeve parts.Gear sleeve parts are made of45 gauge steel with geometric shapes including flanges,steps and profiles.In this paper,the metal flow condition and the key process parameters of the gear sleeve parts during the forming process are analyzed by means of professional finite element simulation software DEFORM-3D.By using orthogonal test,the results show that the optimum parameters are:the temperature of blank is 900 ℃,the friction coefficient is 0.16,the preheating temperature of mold is 230℃,the speed of punch is 12mm/s;The friction coefficient was0.08 and the punch moving speed was 12 mm/s.(2)Study on Friction and Wear of warm-cold forming and properties of new water-based polymer lubricant.The friction and wear of the gear sleeve parts in the warm-cold composite forming process was analyzed by using DEFORM-3D software.It was found that the maximum wear depth region of the die was in good agreement with the die temperature distribution region,and the influence of the key process parameters on the maximum wear depth of the die is obtained.(3)Study on the Characteristics of a New Water-based Polymer Lubricant.Combined with the theoretical study of domestic and foreign cold extrusion lubricants,a new water-based polymer lubricant with PTFE,boron nitride and attapulgite as lubricating materials was prepared.And it makes a comparative testing with domestic and foreign commonly used lubricants by using friction and wear test,the ring upsetting Rough test,gear sleeve part of the crowded gear process test and the gear shaft tooth-shaped area ultra-depth of field observation test.The results show that new water-based polymer lubricant has better lubricating effect than the Phosphorus saponification lubricant,and friction coefficient of it is about 0.058,which can be used in the actual production process of cold extrusion.New water-based polymer lubricant not only compliance with the development of green manufacturing requirements,but also provides favorable support for practical extension and theoretical study of cold extrusion lubricants.