基于Deform-3D的汽车差速器壳体模锻工艺改进  

Improvement on die forging process for automobile differential housing based on Deform-3D

作　　者：郭静[1] 李明星[1] Guo Jing;Li Mingxing(Department of Automotive Engineering,Sichuan Vocational and Technical College of Communications,Chengdu 611130,China)

机构地区：[1]四川交通职业技术学院汽车工程系,四川成都611130

出　　处：《锻压技术》2023年第4期38-47,共10页Forging & Stamping Technology

基　　金：国家自然科学基金资助项目(61179074)。

摘　　要：以汽车差速器壳体为研究对象,为改变目前效率低、壳体性能差、材料浪费多、易出现充不满缺陷的生产现状,开发了一套无飞边模锻工艺,并基于Deform-3D有限元平台进行研究。根据零件的材料和结构拟定了两种不同的成形方案,并通过Deform-3D建立了有限元模型,完成了热力耦合数值模拟,分析了两种方案的成形可行性,并对比了两种方案的优劣。结果表明:采用大直径坯料方案时,各工序间的变形量分布更恰当,材料流动更为合理,成形的差速器壳体的金属流线连续性更好,外形成形完整,无折叠、断裂、空穴等问题,并且锻后温度分布情况更佳,而采用小直径坯料方案获得的差速器壳体锻件存在折叠问题。最后,采用大直径坯料方案进行了锻造试验,获得了符合要求的差速器壳体,完成了新工艺的开发。For the automobile differential housing,in order to change the current production status of low efficiency,poor housing performance,excessive material waste,and easy to have insufficient filling defects,a set of flash free die forging process was developed and studied based on Deform-3D finite element platform.Then,two different forming schemes were worked out according to the material and structure of part,and the finite element model was established by Deform-3D to conduct the thermal mechanical coupling numerical simulation.Finally,the forming feasibility of the two schemes was analyzed,and the advantages and disadvantages of the two schemes were compared.The results show that when the large-diameter billet scheme is adopted,the deformation amount distribution between each process is more appropriate,the material flow is more reasonable,the metal streamline continuity of the formed differential housing is better,the shape is complete,there are no problems such as folding,fracture,holes and other problems,and the temperature distribution after forging is better,while the differential housing forgings obtained by the small-diameter billet scheme have folding problem.At last,the forging test is carried out by using the large-diameter billet scheme,and the differential housing meeting the requirements is obtained,and the development of the new process is completed.

关 键 词：差速器壳体 无飞边模锻 大直径坯料 小直径坯料 金属流线 

分 类 号：TG316.3[金属学及工艺—金属压力加工]