基于滑动模具的某车后桥壳内高压成形的仿真分析

Simulation analysis of internal high pressure forming on the rear axle shell of a vehicle based on sliding mold

针对某车后桥壳内高压成形技术,为了研究其成形规律,降低实验成本,选用与后桥壳具有相同形状特征的三通管进行内高压成形实验并借助有限元软件DYNAFORM对其成形过程进行数值模拟,通过与实验结果对比验证了模型建立及仿真分析的正确性。基于此,根据某车后桥壳成形工艺要求设计成形模具,并利用有限元软件对其成形过程进行仿真,对比模具静止与滑动条件下所得管件的壁厚分布及成形情况。结果表明,模具滑动带动材料进入胀形部分,有效提高了成形质量。在此基础上,进一步研究了模具的不同滑动方式对管件成形的影响规律,为工程应用提供必要的参考。

For the internal high pressure forming technology of rear axle shell of a car,in order to study the forming law and reduce the experimental cost,the internal high pressure forming experiment of the three-way pipe with the same shape characteristics as the rear axle shell was conducted,and the forming process was simulated by the finite element software DYNAFORM. Then,the correctness of the model establishment and simulation analysis were verified by comparing with the experimental results. Furthermore,the forming die was designed according to the forming process of the rear axle shell of a car,and the forming process was simulated by finite element software.Finally,the wall thickness distribution and the forming of the pipe obtained under the static and sliding conditions of the die were compared. The results show that the die sliding can make material into the bulging area and effectively improve the forming quality. Thus,the influences of the different sliding modes of the die on the forming of the pipe were further studied which provided necessary reference for engineering application.