汽车变速器花键轴冷精锻成形有限元分析及试验研究

Finite element analysis and experimental study on cold precision forging for automotive transmission spline shaft

为提高某种汽车变速器花键轴的生产效率,同时保证生产质量和控制生产成本,对花键轴的整体结构进行了分析并设计了一套6工位冷精锻成形工艺。研究了花键轴材料的冷变形行为,并为模拟试验建立了比较准确的本构模型。通过Deform-3D软件详细分析了花键轴的冷精锻成形过程,发现了工位5中存在折叠缺陷,根据金属流动过程确定了缺陷起因,并对工位3和工位4的模具型腔进行了合理优化。试验结果表明,优化工艺能有效解决折叠缺陷,得到的花键轴成形完整且内部质量较好。此外,还对优化工艺进行了冷精锻试验,制得的花键轴产品外观较好,断面流线连续、分布有序,无明显缺陷,与模拟结果高度吻合,验证了优化工艺的有效性。

In order to improve the production efficiency of a certain automobile transmission spline shaft and ensure the production quality and control the production cost,the overall structure of spline shaft was analyzed,and a six-station cold precision forging process was de-signed.Then,the cold deformation behavior of spline shaft material was studied,and a more accurate constitutive model was established for the simulation test.Furthermore,the precision forging process of spline shaft was analyzed in detail by software Deform-3D,and the folding defect in the fifth station were found.Finally,the cause of the defect was determined according to the metal flow process,and the mold cavities of the third station and the fourth station were reasonably optimized.The test results show that the optimized process can ef-fectively solve the folding defect,and the obtained spline shaft has a complete shape and good internal quality.In addition,the cold preci-sion forging test of the optimized process is carried out,and the produced spline shaft product has a good appearance,continuous cross-sectional streamlines,orderly distribution,and no obvious defects,which is highly consistent with the simulation results and verifies the effectiveness ofthe optimized process.