基于数值模拟的变速箱轴套精锻工艺评估及试验研究  

Evaluation and Experimental Research on Precision Forging Process of Gearbox Shaft Sleeve Based on Numerical Simulation

作　　者：田亚丁 刘德波[2] TIAN Yading;LIU Debo(School of Intelligent Manufacturing,Xinxiang Vocational and Technical College,Henan Xinxiang 453006,China;Engineering Department,Huanghe S&T University,Zhengzhou 450006,China)

机构地区：[1]新乡职业技术学院智能制造学院,河南新乡453006 [2]黄河科技学院工学部,郑州450006

出　　处：《精密成形工程》2024年第1期192-200,共9页Journal of Netshape Forming Engineering

基　　金：2021年度河南省科技厅科技攻关项目(212102210249)。

摘　　要：目的针对汽车变速箱轴套在精锻工艺设计阶段成形方案选择多、成形结果不确定的现象,解决试验成本高,开发周期长的问题。方法采用有限元模拟和工艺评价数学模型进行协同研究。首先,针对各工艺方案建立有限元分析模型,分别进行成形模拟,根据成形后零件的填充情况和截面流线状况来评估工艺的合理性;其次,利用工艺评价数学模型将各方案模拟获得的最大应力、最大应变、最大损伤值、最大载荷等重要参数进行整合,以零件质量和模具寿命作为综合评估对象,根据评价值确定最优方案,同时对各方案下的载荷情况进行分析;最后,按照最优方案完成制模和试模生产。结果获得的变速箱轴套成形饱满,质量好,表面无明显缺陷,与模拟结果一致,验证了开发过程的准确性,且尺寸符合要求,内部探伤无裂纹。结论提出的开发工艺可靠,与切削工艺相比,生产效率大幅提升,同时材料利用率提高到92.7%。The work aims to solve the problems of high experimental cost and long development cycle caused by multiple selection of forming schemes and uncertain forming results in the precision forging process design stage of automotive gearbox shaft sleeve.The finite element simulation technology and the mathematical model of process evaluation were used for collabo-rative research.Firstly,the finite element analysis model was established for each process scheme,and the forming simulation was carried out respectively.Then,the rationality of the process was evaluated according to the filling condition and cross-section streamline condition of the formed parts.Next,the process evaluation mathematical model was used to integrate the most important parameters such as maximum stress,maximum strain,maximum damage value and maximum load obtained through simulation of each scheme.The quality of parts and die life were taken as the comprehensive evaluation object,and the optimal scheme was determined according to the evaluation value,and the load situation under each scheme was analyzed.Finally,according to the optimal scheme,die making and trial production were completed.The obtained gearbox shaft sleeve had a full and high-quality shape,with no obvious defects on the surface,which was consistent with the simulation results and veri-fied the accuracy of the development process.The dimension met the requirements and no cracks were found in internal inspec-tion.The proposed development process is reliable,and compared with the cutting process,it significantly improves the produc-tion efficiency,while increasing the material utilization rate to 92.7%.

关 键 词：变速箱轴套 精锻工艺 有限元模拟 工艺评价数学模型 流线 

分 类 号：TG386.3[金属学及工艺—金属压力加工]