汽车桥壳机械式胀形数值模拟及实验

Numerical simulation and experimental study on the mechanical bulging process of axle housing

基于有限元分析软件MARC平台建立汽车桥壳胀形三维有限元模型,采用理论分析、计算机数值模拟和物理实验相结合的方法研究桥壳机械式胀形工艺。对该工艺坯料变形区的受力状态,及易产生折叠和拉裂的潜在区域进行分析与预测,获得金属流动、应力应变分布及壁厚的变化规律;采用无缝钢管在630kN压力机上进行物理实验,验证工艺方案的可行性。实验结果表明,采用机械式胀形工艺方案试制的桥壳成形效果较好,测量的壁厚分布规律与有限元模拟结果吻合,可为桥壳批量化生产提供参考依据。

A three-dimensional finite element model of the axle housings bulging was established based on finite element analysis software MARC platform. Theoretical analysis, numerical simulation and physical tests were combined to research the forming laws during bulging process. Stress state of deformation was analyzed in order to forecast the tendencies of fold and pull cracks. Numerical simulation revealed the flow of material, stress-strain distribution and the variation of wall thickness. Finally, the forming process was tested using seamless steel tube on 630kN press machine. Results showed that the mechanical bulging process of axle housing is feasible. The variation of wall thickness agreed with the numerical simulation. This research can be regard as a reference for the mass production of axle housing.