驱动桥壳阶梯轴内壁精密整形工艺设计及理论解析  

Design and theoretical analysis of inner wall precise reshaping technology for stepped shafts of drive axle housing

作　　者：李攀 罗建国 陈彬 陈梦 王野驰 吕闯 LI Pan;LUO Jian-guo;CHEN Bin;CHEN Meng;WANG Ye-chi;LChuang(College of Mechanical and Electrical Engineering,North China Institute of Science and Technology,Langfang 065201,China;Hebei Key Laboratory of Safety Monitoring of Mining Equipment,Langfang 065201,China;Wuhu BENTELER-POSCO Automotive Co.,Ltd.,Wuhu 241009,China)

机构地区：[1]华北科技学院机电工程学院,河北廊坊065201 [2]河北省矿山设备安全监测重点实验室,河北廊坊065201 [3]芜湖本特勒浦项汽车配件制造有限公司,安徽芜湖241009

出　　处：《塑性工程学报》2020年第8期10-17,共8页Journal of Plasticity Engineering

基　　金：中央高校基本科研业务经费资助项目(3142018012,3142018005,3142019055);河北省高等学校科学研究项目(Z2019052,2018102006230);廊坊市科学技术研究与发展计划自筹经费项目(2019013079)。

摘　　要：根据驱动桥壳端部阶梯轴的形状结构特点,提出了适用于驱动桥壳一体化制造的阶梯轴内壁精密整形新工艺。设计了次序抽芯整形过程的动可容速度场,并基于上限法理论推导了抽芯整形载荷的上限解公式。以13 t卡车驱动桥壳为研究对象,确定了抽芯整形速度和整形芯的半锥角对抽芯整形载荷的影响规律,并结合安全系数划分了抽芯整形速度和整形芯的半锥角取值的允许范围和失效范围。基于有限元软件DEFORM-3D对驱动桥壳阶梯轴缩径及内壁整形过程进行了数值模拟,对首序抽芯整形和次序抽芯整形过程进行了比较,并将数值模拟载荷值与载荷的上限解进行了对比。结果表明:当抽芯整形速度确定时,抽芯整形载荷随整形芯半锥角的增加而升高;当整形芯半锥角确定时,抽芯整形载荷随抽芯整形速度的增加呈升高的趋势。次序抽芯整形比首序抽芯整形进行的时长更长,且抽芯整形载荷的峰值更高。次序抽芯整形数值模拟得到的最大载荷小于上限解但相差不大,验证了所推导的抽芯整形载荷上限解公式的正确性和所提出新工艺的可行性。According to the shape and structure characteristics of stepped shafts at the end of drive axle housing,a new precise reshaping technology for the inner wall of stepped shafts applicable for integrated manufacturing of drive axle housing was put forward,and the kinematically admissible velocity field of second core pulling and reshaping process was designed.Based on the theory of upper limit method,the upper limit solution formula of core pulling and reshaping load was derived.The influence law of core pulling and reshaping speed and half cone angle of the reshaping core on core pulling and reshaping load was obtained by taking a 13 t truck drive axle housing as the research object,and the allowable range and failure range of core pulling speed and half cone angle of the reshaping core were divided combining with the safety factor.Numerical simulation of the process of necking and inner wall reshaping of the stepped shaft of drive axel housing was carried out based on DEFORM-3 D software,and the process of initial core pulling and second core pulling and reshaping process was compared,and the numerical simulation load value was compared with the upper limit solution of load.The results show that the core pulling and reshaping load increases with the increase of half cone angle of the reshaping core when the core pulling and reshaping speed is determined;the core pulling and reshaping load increases with the increase of core pulling and reshaping speed when the half cone angle of reshaping core is determined.The duration of the second core pulling and reshaping is longer than that of initial core pulling and reshaping,and its peak value of core pulling and reshaping load is higher.The maximum load obtained by numerical simulation of second core pulling and reshaping is less than the upper limit solution but the difference is little,which verifies the correctness of the upper limit solution formula of core pulling and reshaping load and the feasibility of the new proposed process.

关 键 词：驱动桥壳 阶梯轴内壁 抽芯整形 上限解 数值模拟 

分 类 号：TG376.2[金属学及工艺—金属压力加工]