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针对精冲成形齿形件时的齿顶塌角问题,首先分析了齿形零件的几何特征及精冲成形特点,并分析了这些特征与齿形零件精冲时齿顶塌角的关系;将精冲变形区分为2个核心变形区和2个变形影响区,对核心变形区Ⅰ精冲塌角的形成过程进行了分析。然后,通过有限元模拟软件Deform-3D,找出齿顶塌角处材料在成形过程中的流动规律。结果表明:齿顶处A面轮廓附近的材料沿齿顶径向运动,一部分材料流向齿顶外侧;齿廓B、C侧附近的材料沿其轮廓线所指向的齿顶方向流动。再次,全面分析了影响精冲齿顶塌角大小的各种因素,找出压边力和反顶力对塌角大小的影响规律,得出反顶力比压边力对控制塌角的效果更显著。最后,提出了在齿形零件精冲成形过程中减小或消除齿顶塌角的具体措施对策。
Aiming at the problem of tooth crown collapse when fine blanking profiled tooth profile, the geometric characteristics and fine blanking forming characteristics of profiled profile parts are firstly analyzed, and the relationship between these features and the crowning profile of tooth profile when fine blanking is analyzed. The fine blanking deformation is divided into two core deformation zones and two deformation influence zones, and the forming process of the fine blanking angle in the core deformation zone I is analyzed. Then, through the finite element simulation software Deform-3D, find out the law of the material flow at the tooth crest during the forming process. The results show that the material near the tip A surface moves radially along the tooth top and a part of the material flows to the outside of the addendum. The material near the tooth flanks B and C flows in the direction of the tooth tip to which the contour lines point. Thirdly, a comprehensive analysis of the various factors that affect the size of the top of the blanking tooth crest is carried out to find out the influence law of the pressure bump force and the anti-tip force on the size of the collapse bump. More significant. Finally, the countermeasures to reduce or eliminate the tooth crown collapse during the fine blanking of the toothed part are proposed.