多楔轮轮毂冲锻成形工艺及影响因素研究

Research on stamping-forging forming process and influencing factors of multi-wedge wheel hub

针对某筒形多楔轮轮毂零件的结构特点,基于板料近净成形原理,对其轮毂成形制定了多道次冲锻工艺方案。基于DEFORM-3D软件平台建立了多道次冲锻成形全流程三维有限元模型,通过数值模拟研究了模具结构参数对缩径翻边和镦锻工序中成形缺陷的影响,并分析了成形过程中的等效应变分布与轮毂筒壁壁厚变化情况。结果表明,当两道次缩径翻边步长l1和l2的取值范围为12.8~15.6 mm、第1道次缩径翻边圆角半径r1不小于16 mm时,轮毂筒壁成形结果良好,没有产生失稳和削料。当整形上模圆角半径R为3.5 mm时,镦锻末期在筒壁与凸缘交接处不会产生折叠缺陷。根据模拟结果进行实验验证,成功试制出多楔轮轮毂,验证了工艺制定及参数选择的可靠性,并最终在此基础上制得合格的多楔轮零件。

Aiming at the structural characteristics of a cylindrical multi-wedge wheel hub,based on the principle of near-net forming of sheet material,the multi-passes stamping-forging process scheme was developed.Based on DEFORM-3D software platform,the three di-mensional finite element model of the whole process of multi-passes stamping-forging forming was established.Numerical simulation was conducted to study the influence of the die structure parameters on the formation defects during the diameter reduction-flanging and upset-ting-forging process,and the distribution of equivalent strain and the change of thickness of the wheel hub cylinder wall during the forming process were analyzed.The results show that when the step lengths l1 and l2 of the two-passes diameter reduction-flanging are 12.8-15.6 mm and the diameter reduction-flanging fillet radius r1 of the first pass is not less than 16 mm,the wheel hub cylinder wall is well formed and no instability and cutting material are produced.When the shaping upper die fillet radius R is 3.5 mm,no folding defects are produced at the junction of the cylinder wall and the flange at the end of upsetting-forging.Based on the simulation results,a multi-wedge wheel hub was successfully fabricated on experiment to verify the reliability of the process development and parameter selection,and a qualified multi-wedge wheel part was finally produced on this basis.