Research on the deformation mechanism for current-assisted splitting spinning forming of small-module gear-shaped parts with extreme diameter-to-module ratios

IF 5.4 2区 工程技术 Q2 ENGINEERING, MANUFACTURING
Qinxiang Xia , Haoyang Zhou , Gangfeng Xiao , Sizhu Cheng , Junhao Zhang
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Abstract

Small-module gear-shaped parts (SMGSPs, module m < 1) with extreme diameter-to-module ratios (D/m>100) are critical components in miniature precision systems for spatial transmission and lightweight structural applications. However, it exhibits restricted fatigue strength and excessive material wastage when manufactured by conventional machining processes. A novel current-assisted splitting spinning forming (CASSF) method combining the precision of spinning technology with the electroplastic effects of pulsed current synergistically was proposed to realize the high-performance near-net shape forming of SMGSPs. A finite element model coupled with the electroplasticity effect is constructed. Finite element model (FEM) simulations and experimental studies systematically investigated the distribution of the electric field, temperature field, the equivalent stress and strain, and the dynamic material flow of small module gears during CASSF. The results revealed that the current density of the SMGSP is concentrated near the contact area of the roller, so the softening region, due to the electroplasticity effect, highly overlaps with the deformation region of the SMGSP. The gear profile deformation exhibits a non-uniform stress-strain distribution, with peak stress concentrations localized at the exit-side tooth root arc. The application of pulsed current effectively reduced equivalent stress and enhanced material deformability, achieving saturation thresholds at 17.5 A/mm² current density (Jp) and 40 % duty ratio (d). Five distinct material flow orientations develop during CASSF, forming four flow division surfaces between them. The uneven tooth height defect originates from asymmetric material flow between the entry and exit sides, whereas tooth underfilling stems from insufficient axial material flow. A forward-reversed forming strategy with intensified pulsed current eliminated tooth height discrepancies and improved tooth saturation (γ) to 97.8 %, demonstrating the potential of CASSF potential for forming extreme ratio SMGSPs.
极径模比小模数齿轮件电流辅助劈裂旋压成形变形机理研究
具有极径模比(D/m>100)的小模块齿轮形零件(smgsp,模块m <; 1)是用于空间传动和轻量化结构应用的微型精密系统的关键部件。然而,当用传统的加工工艺制造时,它表现出有限的疲劳强度和过度的材料浪费。为了实现smgsp的高性能近净成形,提出了一种将旋压技术的精度与脉冲电流的电塑性效应协同结合的电流辅助分裂旋压成形方法。建立了考虑电塑性效应的有限元模型。通过有限元模型仿真和实验研究,系统地研究了小模数齿轮在CASSF过程中的电场、温度场、等效应力和应变分布以及动态物质流动。结果表明:SMGSP的电流密度集中在滚子接触区附近,因此由于电塑性效应,SMGSP的软化区与变形区高度重叠;齿形变形呈现非均匀应力应变分布,应力峰值集中在齿根弧出口处。脉冲电流的应用有效地降低了等效应力,增强了材料的变形能力,达到了17.5 A/mm²电流密度(Jp)和40 %占空比(d)的饱和阈值。在CASSF过程中,形成了五种不同的物质流动方向,在它们之间形成了四个流动划分面。齿高不均匀缺陷是由于进、出口侧物料流动不对称造成的,而齿深充填是由于轴向物料流动不足造成的。脉冲电流增强的正反向成形策略消除了齿高差异,并将齿饱和度(γ)提高到97.8% %,证明了CASSF潜力形成极端比smgsp的潜力。
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来源期刊
CIRP Journal of Manufacturing Science and Technology
CIRP Journal of Manufacturing Science and Technology Engineering-Industrial and Manufacturing Engineering
CiteScore
9.10
自引率
6.20%
发文量
166
审稿时长
63 days
期刊介绍: The CIRP Journal of Manufacturing Science and Technology (CIRP-JMST) publishes fundamental papers on manufacturing processes, production equipment and automation, product design, manufacturing systems and production organisations up to the level of the production networks, including all the related technical, human and economic factors. Preference is given to contributions describing research results whose feasibility has been demonstrated either in a laboratory or in the industrial praxis. Case studies and review papers on specific issues in manufacturing science and technology are equally encouraged.
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