同步器齿环模锻金属流动规律分析及工艺改进
Analysis of Metal Flow and Technology Improvement on Synchronizer Ring Precision Die-forging
王梦寒， 邵长伟， 徐志敏， 周 杰
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作者单位：重庆大学 材料科学与工程学院，重庆 400044
中文关键字：同步器齿环； 金属流动控制； 均匀变形； 数值模拟； 裂口缺陷
英文关键字：synchronizer ring; metal flow controlling; uniform deformation; FEM; split defect
中文摘要：分析了同步器齿环模锻成形过程的金属流动特点，针对同步器齿环模锻成形后花键附件齿顶存在裂口的问题，为改善金属的充模流动状态，提出将齿形的充填由金属的径向流动为主变为轴向镦挤流动为主的模式。应用刚塑性有限元理论及数值软件，对同步环的模锻过程进行了模拟，得出齿顶裂口的原因是齿顶金属充不满所致。通过加大环坯的内、外直径，改变了环坯在模具型腔中的定位，工艺改进有效的改善了齿形形成过程中金属的径、轴向流动状况。模拟结果显示，工艺改进后，花键上方齿顶成形饱满。批量生产后的产品检测未发现齿顶有裂口。
英文摘要：The metal flow ruler in synchronizer ring forging process was analyzed. In order to eliminate the split on the top of gear next to spline during forging process, the radial extrusion was replaced by the method of upsetting and extruding to optimize metallic flow actions. The forging process was simulated by rigid-plastic finite element model combining with FEM software. The results show that the major factor causing split is difficult filling on the top of tooth. The metallic radial and axial flow actions of ring tooth forging are optimized by extending inside and external diameter of blank and modifying the blank positioning mode. The results show that the new process achieves synchronizer ring with full teeth. The split doesn't appear in the tooth top of quantity production rings.