汽车桥壳胀-压成形工艺压制过程的数值模拟

Simulating Bulging-pressing Process in Compound-deforming of Automobile Axle Housing

根据汽车桥壳胀-压复合成形工艺压制过程的基本步骤,通过ABAQUS有限元模拟软件对汽车桥壳压制过程进行数值模拟。研究了汽车桥壳压制过程中模具运动方式以及预制坯内部压强大小对桥壳成形件质量的影响,确定了最佳的桥壳压制模具运动方式以及预制坯内部压强的大小,并进一步分析了理想桥壳成形件壁厚分布情况。模拟结果表明:汽车桥壳胀-压复合成形工艺压制过程中,当压制模具同时运动且预制坯内部压强为30 MPa时桥壳成形件的成形质量最佳。在最佳成形条件下,桥壳成形件中间壁厚最薄,最薄壁厚为3.2 mm且大于初始设计最薄厚度,桥壳的轮廓清晰、过渡圆角大小合适且没有破裂或飞边失效,满足汽车桥壳的设计要求与使用要求。

According to the basic procedures of bulging pressing compound-deforming of automobile axle housing,we simulate the pressing process with the finite element simulation software ABAQUS,study the influence of mold movement method and internal pressure on the quality of automobile axle housing in the pressing process,determine the best mold movement pattern and the size of internal pressure,and analyze the wall thickness distribution of the ideal automobile axle housing. Computer simulation results show that: 1) during the pressing process of bulgingpressing compound-deforming of automobile axle housing,when the pressing mold is moving and the internal loading pressure is 30 MPa,the automobile axle housing has the best quality; 2) with the best condition,the thinnest wall appears in the center of forming part and the thinnest wall is 3.2 mm and bigger than the initial design thickness. The automobile axle housing contour is clear; the fillet size is appropriate; there is no rupture or fly edge failure. All these meet the design requirements for automobile axle housing.