In order to analyze the influence of rolling process parameters on rolling process, orthogonal test method was used to analyze three levels and three factors. The process parameters are temperature, extrusion speed and friction coefficient, and three levels are selected as variation factors for each process parameter.
The range analysis of the test data is carried out by the comprehensive balance analysis method, and the analysis results of material equivalent stress, equivalent strain and forming load are obtained. Where ki (I = 1,2,3) is the sum of the same level value of each factor under different simulation conditions, which reflects the influence of each factor at different levels on the target. KJ is the average value corresponding to Ki, that is, kJ = ki / 9. In the table, R represents the range, i.e. the difference between the maximum value and the minimum value. R reflects the influence degree of a certain factor on the test. The greater R is, the greater the influence of the factor on the target is; otherwise, the influence degree of the factor is smaller.
Based on the data of R value, the following results can be obtained.
(1) Forming temperature, feed rate and friction factor have certain influence on the equivalent stress of billet, in which the feed speed of roller has the greatest influence, the temperature has the second effect, and the friction factor has the least influence.
(2) The influence of the three factors on the equivalent strain of the blank has little difference, that is, the forming temperature, feed speed and friction coefficient have little influence on the equivalent strain of the material.
(3) In the aspect of forming load, the higher the temperature, the smaller the feed rate and the smaller the forming load. It is found that the temperature has the greatest influence on the forming load, followed by the feed speed, and the friction factor has little effect.
To sum up, the influence degree of the three process parameters on the gear forming quality is feed speed, forming temperature and friction factor. In order to reduce the forming load and improve the forming quality, the optimal process combination can be obtained by simulation test and range analysis as follows: forming temperature 950 ℃, friction coefficient 0.1, extrusion speed 0.1 mm / s.
Through three factors and three levels orthogonal simulation test analysis of forming temperature, feed speed and friction factor of gear rolling forming process, the following conclusions are drawn: in the rolling process, feed speed has the greatest influence on material equivalent stress; three factors have little influence on material equivalent strain; forming temperature has the greatest influence on forming load.