多楔带轮旋压成形工艺及缺陷分析

Analysis of spinning process and defects for multi-wedge belt pulley

文章采用旋压工艺替代传统机加工工艺成形多楔带轮。针对物理实验中产生的旋压裂缝以及飞边缺陷,运用有限元模拟分析了变形区域的材料流动情况、应力分布以及缺陷的形成机理。结果表明,多楔带轮在增厚成形过程中,其端部区的材料流动速度低于口部区的材料流动速度,造成端部区的材料积累,形成飞边;在端部与侧壁相交处出现材料不足,径向、周向、轴向最大应力值均超过材料抗拉强度,导致产生旋压裂缝。通过增加一个凹形预成形旋轮,对旋压工艺进行改进,在CDC-S80旋压机上进行试验,消除了旋压裂缝以及飞边缺陷。

The traditional machining processes was replaced by spinning processes to produce multi-wedge belt pulley.To avoid the cracking gap and flash defects in physical spinning experiments,the material flow,stress distribution and defects formation mechanism in the deformed area were analyzed by using finite element simulation.The result shows that,during the process of thickening formation of multi-wedge belt pulley,the material flow velocity in end region is lower than that in mouth region,which leading material accumulation in end region and forming flash.There is lack of materials at the intersection of the side wall and end region and the maximum radial stress,circumferential stress and axial stress all surpass the tensile strength of the materials which causing the spinning gap.Through adding a concave preforming spinning roller and improving the spinning process,the spinning gap and flash is removed for the experiments on CDC-S80 spinning machine.