微型行星齒輪組之太陽齒輪冷鍛成形製程開發

Study on Cold Forging Process for Sun Gear of the Micro Planetary Gear Train

林奕成(I-Chen Lin) ； 王心德(Hsin-Te Wang) ； 鄭淙仁(Tseng-Jen Cheng)

《鍛造》 19卷2期 (2010/06) Pp. 31-36

https://doi.org/10.29791/Forging.201006.0005

摘要

本研究針對齒輪模數0.12mm的微型太陽齒輪進行冷鍛成形製程設計與模具開發。材料為AISI1015，尺寸精度≦6μm，開發齒輪模數≦0.12mm，齒數為13齒，壓力角20度，齒輪高度為1.33mm，徑／寬比約為1.17（節圓直徑／齒寬），太陽軸高0.9mm。利用CAE分析軟體－DEFORM預測太陽齒輪成形負荷與模具受力狀態，作為模仁壓配補強的設計與沖頭鍛打之參考依據。由於微齒輪尺寸較小，在製造與組立模具上也相對困難。針對複動化模具設計需考量適當的複動程序與相互固鎖方式，搭配精微量測設備與模具拋光方式的相互輔助。有鑑於太陽齒輪有單邊軸心的設計，必需考量沖頭雙向動作之鍛造行程來設計模仁分模位置，以減少毛邊產生。最後成形試驗結果顯示微型太陽齒輪冷鍛成形表面粗糙度良好，無夾料缺陷，可作為大量生產參考方式。

並列摘要

In this studying, layout design of cold forging is developed for the micro sun gears which are 0.12 gear modulus. The parameters of micro gear are 0.12mm of gear modulus, 20 degree of pressure angle, and 13 of gear teeth. The contact width of gear surface is 1.33mm. One side circular shaft is 0.9mm of the outside diameter and 1.0mm of the length. The ratio of diameter of pitch circle to gear width is 1.17. AISI 1015 is the material of billet. The state of material flow is observed through FEM simulation. Stress and strain of billet and mold are also evaluated to choose the material of die after simulated analysis. The die of doubled action and ring reinforcement of cavity are considered as important factors in the die and mold design. Since the dimension of micro gear is compact, the manufacture and assembly of components and molds are also great challenges. The die cavity is polished with fine powder and precisely measured by optical measurement. The parting lines of dies are also evaluated to reduce the occurrence of burr. The results of forging test show that the surface roughness of micro sun gear is smooth and there is no lapping defect. Finally, this method that manufactures a considerable number of micro gears is obtained.