基于有限元模拟的车用齿轮轴冷镦工艺研究与试验验证

Research and experimental verification on cold heading process for automotive gear shaft based on finite element simulation

针对一种复杂车用齿轮轴加工困难、产量低、费材、使用性能差等问题,采用冷镦加工工艺进行生产。首先,根据齿轮轴的结构特点初步确定了成形方法、成形工位数及各工位的零件外形;其次,利用Deform-3D软件对拟定工艺的各个工位进行了有限元建模和成形过程仿真。同时,为起到有效的预测和检验作用,通过压缩试验研究了生产材料的室温变形行为,并在Deform-3D中创建了相应的流动应力模型。模拟结果表明:各工位的零件成形结果符合设计要求,外形完整,无缺肉现象,同时成形时金属变形合理,流线情况较好,材料损伤也处于安全范围内,无折叠、开裂等问题。最后,根据制定的工艺完成了齿轮轴的7工位冷镦试验,获得的所有产品的质量均较好,与模拟结果高度吻合,说明新工艺可行、可靠,有效解决了复杂车用齿轮轴的实际生产难题。

For the problems of difficult processing,low output,waste of materials and poor service performance of a complex automo-tive gear shaft,the cold heading processing process was adopted.Firstly,based on the structural characteristics of gear shaft,the forming method,the number of forming stations and the shape of parts at each station were preliminarily determined,and then,the finite element modeling and forming process simulation of each station for the proposed process were carried out by Deform-3D soft-ware.At the same time,in order to provide effective prediction and verification,the deformation behavior of the production material at room temperature was studied by compression tests,and corresponding rheological stress model was built in Deform-3D.The sim-ulation results show that the forming results of parts at each station meet the requirements,with complete appearance and shape in-tegrity.At the same time,the metal deformation during forming is reasonable,the streamline condition is good,and the material damage is also within the safe range without folding,cracking and other problems.Finally,a seven-station cold heading test of gear shaft is conducted according to the established process,and all products obtained have good quality,which is highly consistent with the simulation results indicating that the new process is feasible and reliable,and the actual production problems of gear shaft are effec-tively solved.