重型车半轴套管镦挤成形工艺的研究

发布时间：2019-01-17 20:39

【摘要】：在汽车制造技术迅猛发展的今天,各大汽车厂商不仅仅在整车性能上进行激烈的竞争,在汽车零部件生产上的竞争也日趋激烈,包括新材料的应用、新的成形工艺的研发,这些方面都备受业内关注。其中,与驱动桥壳相连接的半轴套管是主要的、必不可少的零件,承受着整车的全部重量,并且在汽车行驶的过程中,承受着复杂的交变应力,所以说半轴套管的质量是否过关与乘客的生命财产安全息息相关。现在半轴套管的成形技术虽然已经很成熟了,但是普遍采用的成形方案是以棒材为原材料,然后进行多工步成形。这样的成形方案不仅材料利用率低,而且由于工步多,严重影响生产效率,增大了制造误差,造成废品率很高。为了彻底解决以上缺陷,各大厂家积极研发最新的成形工艺,以用来降低成本,以能够适应目前的竞争激烈的汽车零部件市场。所以吉林大学作为汽车行业研发的先锋,提出了以管坯为原材料的一次镦挤成形工艺。本文通过认真分析现有的半轴套管的成形方案,大胆提出了以管坯为原材料的一次镦挤成形工艺,彻底的摒弃了以往的繁琐工序,效率得到大大提高,成本显著降低。一旦实现量产,前景不可估量。本文针对半轴套管新的成形工艺主要对以下几个方面的内容进行了研究:(1)本文根据管材成形的相关理论及半轴套管的几何形状特征,设计了半轴套管锻件图,并通过后期的有限元仿真模拟及实验,验证了锻件图的合理性。依据金属塑性成形前后体积相等的原则及所设计的锻件图,详细计算了管坯的尺寸。最终确定了以管坯为原材料的一次镦挤成形工艺。(2)利用成形软件DEFORM-3D进行有限元仿真模拟,不仅能够验证前边设计的锻件图的合理性,又通过对半轴套管成形结果的详细的分析,论证了以管材为原材料的一次镦挤成形半轴套管的合理性。并且利用正交试验,通过对几个重要的影响参数的优化,探讨了各个影响参数对成形结果影响的大小,并且找到了使得成形载荷最小的工艺参数组合。(3)由于本文中采用的是卧式液压镦锻机成形半轴套管,无先例可以参考,所以设计模具时带来了很大的困难,从多种方案中优选以后,采用了本文所设计的模具结构,凹模分为上下凹模,利用垂直液压缸带动上凹模进行上下行进,用来与下凹模进行开合。其中凹模又创新性的采用了镶块结构,压紧镶块与成形镶块分割开来,有利于模具的更换。在水平方向上,凸模在液压缸的带动下对管坯进行镦挤。(4)针对现有的卧式液压镦锻机进行了详细的理论分析,证明了其能够满足本文中半轴套管的成形。(5)针对以上的研究内容,在车桥厂进行了样件的试制,验证了以上研究内容的合理性。(6)从工程应用价值方面进行分析,证明了本文所研究的成形工艺能够达到高效、经济、环保的效果。
[Abstract]:Today, with the rapid development of automobile manufacturing technology, the major automobile manufacturers are not only engaged in fierce competition in vehicle performance, but also in the production of automotive parts, including the application of new materials and the research and development of new forming technology. These aspects have attracted the attention of the industry. Among them, the half axle casing connected with the drive axle housing is the main and essential part, bearing the full weight of the whole vehicle, and the complex alternating stress in the driving process of the vehicle. Therefore, the quality of half-shaft casing is closely related to the safety of passengers' lives and property. Although the forming technology of half shaft casing is very mature, the commonly used forming method is to take bar as raw material and then multiplex forming. Not only the material utilization ratio is low, but also the production efficiency is seriously affected, the manufacturing error is increased, and the scrap rate is very high. In order to completely solve the above defects, the major manufacturers actively develop the latest forming process to reduce costs, in order to adapt to the current fierce competition in the automotive parts market. Therefore, Jilin University, as the pioneer of automobile research and development, put forward a upsetting extrusion process with tube billet as raw material. In this paper, by analyzing the existing forming scheme of half-shaft casing, a new upsetting and extrusion process with tube billet as raw material is put forward, which completely abandons the previous complicated working procedure and greatly improves the efficiency and reduces the cost significantly. Once mass production is realized, the prospect is incalculable. The following aspects are studied in this paper: (1) according to the theory of tube forming and the geometry characteristics of half shaft casing, the forging drawing of half shaft casing is designed in this paper. The rationality of forging drawing is verified by finite element simulation and experiment. According to the principle of equal volume before and after metal plastic forming and the design of forging drawing, the size of tube blank is calculated in detail. Finally, the process of upsetting extrusion with tube billet as raw material is determined. (2) finite element simulation is carried out by means of forming software DEFORM-3D, which can not only verify the rationality of the forging drawing designed in front, Through the detailed analysis of the forming results of half-shaft casing, the rationality of one-stage upsetting forming casing with pipe as raw material is demonstrated. By using orthogonal test and optimization of several important influence parameters, the influence of each parameter on the forming result is discussed. And found the process parameters to minimize the forming load. (3) because the horizontal hydraulic upsetting machine is used in this paper to form the half shaft casing, there is no precedent to refer to, so the design of the die has brought great difficulties. After the best selection of various schemes, the die structure designed in this paper is adopted. The concave die is divided into upper and lower concave die, and the vertical hydraulic cylinder is used to drive the upper concave die up and down, which is used to open and close with the lower concave die. The die adopts the inlay structure innovatively, and the compaction block is separated from the forming block, which is advantageous to the replacement of the die. In the horizontal direction, the punch is driven by the hydraulic cylinder to upsetting and extruding the tube billet. (4) the theoretical analysis of the existing horizontal hydraulic upsetting forging machine is carried out in detail. It is proved that it can satisfy the forming of the middle axle casing in this paper. (5) in view of the above research content, the prototype is made in the vehicle bridge factory, and the rationality of the above research content is verified. (6) the engineering application value is analyzed. It is proved that the forming process studied in this paper can achieve the effect of high efficiency, economy and environmental protection.
【学位授予单位】：吉林大学
【学位级别】：硕士
【学位授予年份】：2016
【分类号】：U466

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