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For die forging, the cavity is lubricated with 70 oil 30 graphite graphite lubricant. In order to prevent the forging from oxidizing in the air, the forging is cooled in dry sand. The mold is designed to extend the life of the forging die, improve the precision of the forging, facilitate the processing of the mold, and store the excess metal material. Therefore, the closed die forging process is adopted for the friction press with the upper die with the back pressure device. The mold structure is simple and compact, versatile, easy to assemble and adjust, and low in cost. The working parts of the mold are made of H13 and W18Cr4V steel, and the heat treatment hardness is HRC48～HRC52. The toothed cavity of the concave mold is processed by EDM machine.
The technical and economic analysis of the old and new processes uses the advanced precision closed die forging process for double gear production, which has the following advantages: saving materials. The precision closed die forging out the lower gear profile and part of the inner hole can increase the metal material utilization rate from 52.4 to 60.0, and each forging can save 1.2kg. According to the annual output of 30,000 pieces and spare parts 20, the material can be saved by 43.2t. According to the unit price of steel of 4000 yuan/t, the steel cost is saved by 173,000 yuan.
Save energy consumption. The 43.2t steel saved is no longer heated. According to the induction heating, the unit consumption is 0.5kW/kg, which can save 2.16×104kW. Calculated according to the unit price of industrial electricity of 0.53 yuan / kW, the electricity cost is 11.5 million yuan. Improve the quality of forgings. Closed die forging can make the shape of the forged part and the finished part very close or completely consistent, so that the metal fiber is distributed along the tooth profile, and the deformed metal 1 is in the state of three-way compressive stress, which is beneficial to improve the plasticity of the metal material and prevent looseness inside the part. Therefore, the fatigue strength of the gear is increased by more than 30 compared with the conventional die forging. Reduce the amount of machining. Since the shape of the gear is forged and the dimensional accuracy of the forging is increased, the subsequent machining amount of the forging is significantly reduced, in particular, the coarse threading amount is reduced by 66. Increased production capacity. As the amount of coarse insertion is reduced by 66, the "bottleneck" of the production line is solved, and the production capacity is increased by 2 times without increasing the gear shaping machine.
The last sharp tooth of the broach is raised. If it is 0.01 to 0.15, it will increase to 0.02 to 0.025 after regrind, thereby forming annular chips. After many sharpenings, the mutation will become more and more serious, which will affect the surface quality of the broached workpiece. Therefore, it is recommended to select the fine tooth arrangement and the calibration tooth arrangement parameters.