铆焊型液力变矩器涡轮辊铆成形工艺仿真及参数优化

Simulation and Parameter Optimization oF Riveting Process for Turbine Roll of Riveted Hydraulic Torque Converter

以一种典型的铆焊型液力变矩器涡轮为研究对象,针对涡轮装配成型中的外环-叶片-内环的辊铆成形工艺及尺寸开展研究。结合有限元仿真分析和试验手段,研究了叶片支耳的辊铆成形工艺,分析了拨倒、滚压成形工艺参数对滚铆成形精度的影响规律。以叶片材料的拉伸应力-应变曲线及各向异性系数等力学性能测试参数、涡轮总成的三维几何模型、辊铆工况为输入,建立了叶片支耳滚铆成形的有限元模型,采用Abaqus分别建立了支耳拨倒、滚压成形的有限元模型,分析了拨倒角度、滚压进给量和次数对支耳成形后的应力及应变分布、与内/外环的贴合间隙的影响,确定了较为合理的辊铆工艺参数。设计制作了快速滚铆工装,研制了涡轮总成样件,对比分析了样件实物中支耳的贴合度测试数据与仿真结果,验证了工艺参数的合理性。研究结果表明:叶片支耳成形采用3道分3次滚压成形后,回弹量最小,不大于0.1 mm且满足设计技术要求,辊压后支耳的成形应力最小、变形更均匀;经涡轮样件试制验证有限元仿真模型的准确性,误差小于7.7%。

Taking a typical riveted hydraulic torque converter turbine as the research object,this paper studies the rollriveting process and dimensional accuracy between the outer ring,blade,and inner ring during the assembly of the turbine.Combined with the finite element simulation analysis and experimental means,the roll-riveting process of blade lug is studied,and the influence of the rolling parameters on the roll-riveting accuracy is analyzed.Taking the tensile stress-strain curve,anisotropy coefficient and other tested mechanical parameters of the blade material,the three-dimensional geometric model of the turbine assembly and the roll-riveting condition as inputs,finite element model of the rolling riveting forming of the blade lug is established.The finite element models of the rolling and roll-forming of the lug are established using ABAQUS software.The influence of the rolling angle,riveting feed rate and times on the stress and strain distribution after the forming of the lug are analyzed.The reasonable processing parameters of roll-riveting are determined.A kind of rapid-roll riveting device is designed and manufactured,and the turbine assembly samples are developed.The fitting data of the blade lug to the support obtained from the samples and simulation results are compared and analyzed to verify the rationality of the process parameters.The results show that after three passes and three times of roll-forming,the springback of the blade lug is the smallest,by no more than 0.1 mm,and the forming stress is the smallest and the deformation is more uniform after rolling;The accuracy of the finite element simulation model is verified by the trial production of turbine samples,and the error is less than 7.7%.