中文摘要：

齿形充满不充分和成形载荷过大是螺旋锥齿轮锻造近净成形的主要问题.利用弹塑性有限元法模拟螺旋锥齿轮从动轮一火两锻的半闭式锻造过程,提出通过优化预成形件面锥形状以改善轮齿端角隅部位填充不满的现象,运用正交试验优化设计方法,确定预锻件高度、圆弧弦高、圆弧弦角以及圆弧高点离轮齿小端的距离4个工艺因素对轮齿充满程度和成形载荷的影响规律,选出最佳工艺因素组合.在此基础上提出在轮齿小端设计分流腔的模具结构,以进一步改善齿轮小端角隅充满不理想的现象,对比分析两种工艺方案的成形载荷的峰值,分流锻造成形载荷减小了22.45％.在25 MN电动螺旋压力机上进行锻造试验.通过数值模拟和试验结果的对比分析,验证了新工艺方案的有效性.

英文摘要：

Difficult gear tooth corner filling and excessive forming load are the main limitations of spiral bevel gear near net shape forging. Based on the elastroplastic finite element method, the spiral bevel gear forging process using semi-closed die was simulated, and an optimized arc surface cone was proposed for improving the unfilled tooth corner. The influence rules of the processing factors inclu- ding preforrn height, arc chord height, chord angle and the distance between arc peak and the tooth toe, on the tooth corner filling situation and the forming load were revealed. The best combination of processing factors was chosen by orthogonal experimental design. For decreasing the forming load, the die structure with divided flow cavity was designed, from the simulation results, the forming load decreases more than 22.4. The experiments were carried out using 25 MN electric drive screw press. The numerical simulations and experimental results show that the optimized process mentioned herein is effective.