乘用汽车三脚突缘成形工艺研究-材料加工工程专业论文.docxVIP

乘用汽车三脚突缘成形工艺研究 摘 要 随着汽车产业的日益扩大，汽车功能不断提升，行业标准中对汽车零部件的要求 越来越严格，高精度、高强度的锻件更能迎合主流市场。因此，对于汽车零部件制造 厂来说，实现高质量、低成本、高效率的汽车零部件的生产开发，才能在汽车市场中 赢得一席之地。在这种情况下，新的成形工艺的发展以及新材料的开发逐渐受到各汽 车企业的重视。 三脚突缘是乘用汽车传动轴上的零件，用于传递发动机的扭矩和承受弯曲组合载 荷，是乘用汽车传动系中与花键轴连接的重要关键零件之一。该三脚突缘形状较为复 杂，并且端部面成三个分杈枝和凸台，其成形难度大，对成形工艺要求高。探索该类 零件的合理成形方法对我国汽车工业的发展具有重要意义。 为了尽可能降低生产成本，使锻件达到少切削加工的目的，本文根据热锻和热挤 压成形理论，针对乘用汽车三脚突缘零件的自身特点，建立了三脚突缘热模锻成形过 程的三维刚粘塑性有限元模型，采用 DEFORM-3D 有限元软件对三脚突缘模锻成形 过程进行了详细模拟。重新设计了模锻成形工序和各工序模具形状，探索一条适合乘 用汽车三脚突缘生产的途径。另外，对成形模具做相应的模具应力分析以及磨损分析， 预估模具的使用寿命。 本文研制的乘用汽车三脚突缘成形新工艺，为该零件的国产化提供了一条行之有 效的途径，同时工艺研究的成功经验能为类似突缘杈枝零件的成形提供一定借鉴。 关键词：三脚突缘，锻造工艺，半封闭复合挤压，数值模拟，复合模设计 I A STUDY ON FORMING PROCESS OF AUTOMOBILE TRIANGULAR FLANGE ABSTRACT With the automobile industry growing, the property of motors improves constantly, the requirement of automobile parts is more and more strict in terms of industry standard, high strength forgings are more competitive in the market. Therefore, for automobile parts manufacturers, only doing research on high quality, low cost, high efficiency of auto parts can make the manufacturers earn their places in the car market. In this case, the various auto enterprises have an attention to the development of the new forming technology and new materials gradually. Triangular flange is the part of transmission shaft of passenger motor vehicle, which is used to transfer the torque of engine and compound bending load, and it is one of the key and important parts connecting the drive system with spline shaft. The shape of triangular flange is complicated, and there are three branches and convex platform, therefore it is difficult to form and the high requirement of its forming process is needed. It is urgent to solve the problem that how to produce such kind of triangular flange efficiently and economically． In this paper, in order to reduce the production cost as possible, and achieve the purpose of less machining of the forgings, three dimensional rigid visco-plastic finite element model of triang