附加前盖对汽车桥壳胀-压成形性的影响

Effects of Additional Front-dome on Bulging-pressing Formability for Automobile Axle-housing

根据胀-压成形汽车桥壳新工艺,初始无缝钢管经缩径、液压胀形及压制成形后得到带有后油盖及附加前盖的桥壳样件,切除前盖后获得桥壳产品,附加前盖的大小不仅影响材料的利用率,对管坯的压制成形性也有重要影响。针对某小型汽车桥壳,设计了三种不同尺寸、形状的附加前盖,利用有限元分析软件ANSYS模拟了不同附加前盖时桥壳样件的缩径、胀形及压制成形全过程,对比分析了桥包部分的成形性及端部翘曲量,确定了附加前盖的合理尺寸范围。在普通液压机上成功试制出桥壳样件,实际测量了其外形参数,并与模拟值进行了比较,证明了设计方法的可行性。

According to the bulging--pressing deforming new process, an initial seamless steel tube was made into automobile axle--housing blank with additional front--dome after diameter reduc- ing, hydroforming and pressing, and the axle--housing can be gotten once the front--dome was re- moved. The additional front--dome affected the material utilization and the bulging--pressing form- ability. For a small axle--housing, three front--domes with different shapes and sizes were designed, the whole reducing, bulging and pressing deforming processes were simulated with software ANSYS, the reasonable size range for additional front--dome was given by analyzing the formability of dome part and ends buckling. The axle--housing blank was produced successfully with a common press, and the design method was proved to be reasonable comparing shape parameters with simulation re- sults.