乘用汽车三脚突缘成形工艺研究

Study on Forming Process of Automobile Triangular Flange

乘用汽车传动轴中的三脚突缘是一种形状较复杂的零件,在端部面有三个分叉枝和凸台,其成形难度大,对成形工艺要求高。根据三脚突缘锻件的特点,采用一种半封闭挤压代替传统的预锻工艺,利用有限元数值模拟软件DEFORM-3D模拟了半封闭挤压成形和终锻成形过程,获得了相应的载荷—行程曲线、等效应变和等效应力分布规律,并做了相应的模具应力分析。另外,由于锻件所在模具型腔较浅,切边定位困难,为了避免切边时产生错位和变形,将切边、整形工序设计成一套复合模。最后通过小批量试验,验证了三脚突缘成形新工艺的可行性。

Triangular flange of automobile transmission shaft is a kind of complicated shape part, and there are three bifurcation branches and the boss in the end. Its forming is difficult, and the forming requirements are higher. According to the structure characteristic of triangular flange, a new semi-closed extrusion process was proposed instead of traditional pre-forging process. Its deformation process and finish-forging process were simulated by DEFORM-3D software. The load-stroke curves, the distribution of equivalent stress and strain, and the distribution of die stress were obtained by numerical simulation. And the corresponding die stress was analyzed. Besides, in order to avoid the dislocation and deformation when trimming, a set of trimming and shaping composite die was designed. Finally, through a small batch of tests, the feasibility of the new process was verified.