Kev tshawb fawb ntawm Precision Forging Technology ntawm Synchronizer Steel Iav Ring

Lub synchronizer yog ib qho tseem ceeb nyob rau hauv lub tsheb gearbox kom ua tiav kev hloov ceev, thiab lub nplhaib iav yog ib qho tseem ceeb ntawm cov synchronizer. Qhov tseeb thiab zoo ntawm cov iav nplhaib yuav ncaj qha cuam tshuam qhov tshwm sim ntawm kev hloov ceev. Nrog txoj kev loj hlob sai ntawm kev lag luam tsheb, tus thawj tooj liab synchronizer iav rings tau maj mam hloov los ntawm steel synchronizer iav rings. Peb cov khoom siv synchronizer yog ua los ntawm cov khoom siv hlau, uas xav tau heev thiab xav tau ntau lawm. Kab lus no tsuas yog kawm txog cov txheej txheem forging ntawm steel synchronizer iav rings. Cov khoom siv raw yog 20CrMnTi, thiab lub xeev ua ntej precision forging yog ntxhib dov nplhaib dawb paug; Txhim kho a precision forging txheej txheem Txoj kev npaj: ntxhib tig billet → kub precision forging → tig flash → annealing → txhaj tshuaj blasting → polymer kho → txias precision nias. Los ntawm kev txiav txim siab qhov tshwj xeeb ntawm qhov kub precision forging billet (xws li 3D simulation), precision forging pwm tsim thiab tsim, precision forging txheej txheem kuaj, thiab lwm yam, xyuas kom meej tias qhov tsis xws luag xws li folding, cracking, tsis txaus cov hniav, thiab nto roughness tsis tshwm sim. thaum lub sij hawm precision forging txheej txheem. Los ntawm kev txheeb xyuas cov txheej txheem, qhov precision forging txheej txheem ntawm steel synchronizer iav nplhaib yog ua tau; Cov txiaj ntsig 3D simulation tau zoo ib yam nrog cov txiaj ntsig tseeb.

1. Txiav txim siab qhov tshwj xeeb ntawm kub precision forging blanks

Cov hlau synchronizer iav nplhaib tau kawm hauv txoj kev tshawb no yog ua los ntawm 20CrMnTi kub dov puag ncig steel los ntawm kev txiav, cua sov, ua ntej forging, xuas nrig ntaus, thiab lub nplhaib dov. Qhov dawb paug yog tau tom qab tig ntxhib, thiab lub voj voog sab nrauv muaj 3 convex yuam sij thiab 48 cov hniav me me. Lub precision thiab nto roughness yuav tsum tau rau lub convex yuam sij thiab cov hniav me me yog siab: qhov dav sib txawv ntawm convex yuam sij yog ± 0.1 hli, thiab symmetry kam rau ua yog 0.15 hli; Lub convex thiab concave rounded ces kaum ntawm cov hniav me me raws li R0.2mm, thiab lub runout kam rau ntawm cov hniav nyob ib sab yog 0.05mm; Deg roughness yuav tsum tau rau qhov tsis-machined nto Ra3.2 μm. Tom qab precision forging, cov khoom no tsis yog machined lawm.
Theoretical hnyav ntawm lub tiav forging khoom yog 0.27kg. Raws li cov ntaub ntawv empirical, qhov dav ntawm sab hauv thiab sab nraud yog 6-8mm, thiab thickness yog 1.5-2.5mm. Raws li qhov no, tag nrho qhov hnyav ntawm cov khoom txiav yog suav tias yog 0.39kg; Qhov kev xaiv zoo tshaj plaws rau kev tso qhov khoob hauv cov pwm yog cov hniav hauv paus lub voj voog φ Ntawm 113mm, lub taub sab nraud ntawm qhov khoob tuaj yeem hloov kho raws li qhov kev txiav txim siab φ 112mm; Kev siv forging puab qhov loj φ 94mm, thawj zaug xaiv billet puab kab yog φ 88mm φ 90mm φ 92mm φ Muaj plaub hom 94mm billets. Raws li tag nrho qhov hnyav thiab sab hauv thiab sab nraud qhov ntev ntawm cov billets, lub thicknesses ntawm plaub hom billets yog xam los ntawm 13.2mm, 14.2mm, 15.5mm, thiab 17.1mm, feem.
Tom qab 3D software simulation (Daim duab 1), nws tau pom tias qhov ntau thiab tsawg flash ntawm plaub hom billets hais saum toj no txawv, thiab cov khoom tuaj yeem tsim. Cov txiaj ntsig simulation qhia tau hais tias sab hauv thiab sab nraud ntawm 2 # specification billets yog qhov sib xws tom qab tsim, uas yog qhov tsim nyog tshaj plaws thiab yuav tsum tau kuaj xyuas los ntawm cov txheej txheem tom ntej.

Figure.1 3D Simulation Results

2. Tsim thiab tsim cov precision forging pwm

2.1 Cov ntsiab lus tseem ceeb ntawm kub precision forging pwm tsim

Raws li qhov txias precision forging daim duab, qhov sib txawv ntawm ib sab yog txo los ntawm 0.1-0.15mm, thiab lub thickness yog nce los ntawm 0.5-1mm kom tau txais cov kub precision forging daim duab. Lub tshav kub shrinkage tus nqi yog 1.5%, uas tuaj yeem txiav txim siab qhov loj ntawm qhov kub precision forging pwm kab noj hniav. Cov txheej txheem kev tshawb fawb no txais yuav qhib tuag forging, tsim sab hauv thiab sab nraud flash grooves, thiab tsim cov khoom siv sab saum toj ntawm lub flash txoj hauj lwm hauv pwm qis. Siv lub hauv paus pwm loj ntawm cov khoom siv los tsim cov qhov ntev ntawm qhov kub precision forging pwm, cov kab noj hniav pwm cov khoom hauv kev sib cuag nrog cov khoom kub yog ua los ntawm 1.2367 nrog cov xim liab zoo, uas tuaj yeem ua kom cov khoom raug.

2.2 Cov ntsiab lus tseem ceeb ntawm txias precision nias pwm tsim

Cov kab noj hniav loj ntawm qhov txias precision forging tuag yog raws li qhov txias precision forging daim duab, thiab cov qauv ejection zoo ib yam li kub precision forging tuag. Lub qhov ntev ntawm qhov tuag kuj tseem tsim raws li cov khoom qub pwm thav duab, thiab cov hniav zoo li tus tuag yog ua los ntawm LD cov khoom uas muaj siab hardness thiab zoo hnav tsis kam.

2.3 Cov ntsiab lus tseem ceeb rau precision forging pwm raug

Lub pwm kab noj hniav yog ntxhib milled los ntawm high-speed CNC machining chaw, tsim los ntawm hluav taws xob tawm machining tom qab kev kho cua sov, thiab thaum kawg polished los ntawm cov khoom tshwj xeeb polishing.

3. Precision forging txheej txheem kuaj

3.1 Pwm preheating

Siv cov cuab yeej siv cua sov ua ntej ua pwm rau 250-300 ℃, uas yooj yim rau kev sau cov hniav tag nrho thiab tsis yooj yim ua rau pwm tawg.

3.2 Billet cua sov

Kos 20 daim ntawm txhua qhov ntawm 4 qhov ntxhib dov billets thiab sai sai ua kom sov rau 1150-1200 ℃ nyob rau hauv ib tug tshwj xeeb nruab nrab zaus induction cua sov ntaus ntawv.

3.3 Kub precision forging

Lub 630t CNC ntsia hlau xovxwm uas twb muaj lawm yog siv rau kub precision forging (lub simulated tsim quab yuam yog 327-453 tons), thiab cov rhuab blanks yog raug muab tso rau kab rov tav ntawm qhov chaw ntawm lub hauv paus lub voj voog ntawm kub precision forging tuag. Lub voj voog sab nrauv ntawm qhov khoob yog haum nrog lub hauv paus lub voj voog ntawm qhov tuag kom ua tiav qhov chaw seem kom tsis txhob muaj qhov tsis xws luag xws li folding thiab tsis txaus cov hniav thaum lub sij hawm precision forging. Thaum lub sij hawm kub precision forging txheej txheem, cov pwm tso tawm tus neeg sawv cev kuj yuav tsum tau txias thiab lubricate lub pwm.
Tom qab kev txheeb xyuas cov txheej txheem ntawm qhov chaw, qhov kub precision forging txheej txheem xeem tau rau cov hlau synchronizer iav nplhaib zoo ib yam nrog 3D software simulation cov txiaj ntsig. Daim duab 3D qauv thiab cov khoom kub precision forging yog pom nyob rau hauv daim duab 2. Ntawm cov plaub specifications ntawm billets, specification 2 # muaj qhov zoo tshaj plaws forming nyhuv, txawm nyob rau hauv lub puab thiab sab nraud flash qhov ntau thiab tsawg, uas muaj peev xwm xyuas kom meej puv tag nrho cov khoom seem yam tsis muaj forging tsis xws li folding thiab cracking thiab tsis nkim cov ntaub ntawv. Ntawm lwm qhov peb qhov tshwj xeeb ntawm billets, qhov kev sim rau qhov tshwj xeeb 1 # qhia tau hais tias lub voj voog sab nraud me me, muaj ob peb cov hniav uas tsis puv, lub flash sab hauv yog loj, thiab muaj ntau cov khoom pov tseg; Specifications 3 # thiab 4 # muaj cov npoo loj dua.

Figure.2 3D Modeling Drawing thiab Lub Cev Khoom ntawm Kub Precision Forging

3.4 Tsheb trimming

Tom qab qhov kub precision forging dawb paug yog lawm txias, lub flash ntawm lub puab lub qhov thiab lub voj voog yuav raug tshem tawm. Lub teeb nyob rau hauv thickness kev taw qhia yuav tsis raug tshem tawm ib ntus, thiab nws yuav tsum tau siv raws li qhov zoo nias nyiaj pab rau lub tom ntej txias nias. Lub tshuab machining tom ntej yuav tshem tawm lub teeb nyob rau hauv cov kev taw qhia tuab.

3.5 Annealing softening

Cov txheej txheem annealing softens qhov khoob kom yooj yim txias precision sib sau.

3.6 Tua blasting tu

Blast ntxuav lub annealed dawb paug ntawm lub hanging txhaj koob tshuaj tivthaiv blasting tshuab uas twb muaj lawm kom tshem tawm cov oxide ntawm daim tawv nqaij nyob rau saum npoo ntawm qhov dawb paug. Xaiv cov khoom zoo steel nrog lub cheeb ntawm tsawg dua 0.4mm los xyuas kom meej qhov roughness ntawm cov khoom thaum lub sij hawm txias precision nias.

3.7 Polymer kev kho mob

Siv polymer lubrication kev kho mob rau qhov khoob tom qab txhaj tshuaj blasting los txhim kho qhov roughness ntawm cov khoom tom qab txias precision nias thiab lub neej ntev ntawm qhov txias precision nias pwm.

3.8 Txias precision nias

Muab cov polymer-kho dawb paug rau hauv qhov txias precision pressing pwm, siv cov 1600 tuj roj xovxwm uas twb muaj lawm los teem lub siab kom raug, thiab ua qhov txias precision pressing test (qhov kev thov tiag tiag yog li ntawm 1000 tons). Tom qab txhua qhov kev txiav txim siab nias cov khoom, siv rab phom cua siab los tshuab thiab ntxuav cov pwm kab noj hniav. Tom qab kev sim, cov khoom lag luam qhov tseeb thiab qhov roughness tom qab txias precision nias ua tau raws li qhov yuav tsum tau ua ntawm daim duab.

4. xaus

cov forging txheej txheem ntawm kub precision forging + txias precision nias tuaj yeem ua tiav precision forging ntawm steel synchronizer iav nplhaib.
Cov txiaj ntsig ntawm 3D software simulation tau ua raws li qhov kub precision forging txheej txheem kev xeem cov txiaj ntsig ntawm cov hlau synchronizer iav nplhaib, uas tuaj yeem ua tiav cov qauv tsim ntawm cov hlau iav nplhaib pwm, txo cov khoom lag luam kev loj hlob, thiab txo cov nqi kev loj hlob.
Sau: Wang Zixiao