基于数值模拟的汽车差速器壳锻造工艺分析及实验研究  

Analysis and experimental research on forging process of automotive differential housing based on numerical simulation

作　　者：伍贤洪 闫焱[2] Wu Xianhong;Yan Yan(School of Intelligent Manufacturing,Nanning College for Vocational Technology,Nanning 530008,China;Guangxi Key Laboratory of Materials and Processes of Aluminum Alloys,Guangxi Alnan Aluminum Fabrication Co.,Ltd.,Nanning 530031,China)

机构地区：[1]南宁职业技术学院智能制造学院,广西南宁530008 [2]广西南南铝加工有限公司广西铝合金材料与加工重点实验室,广西南宁530031

出　　处：《锻压技术》2024年第9期18-26,共9页Forging & Stamping Technology

基　　金：2023年广西创新驱动发展专项资金(广西科技重大专项)资助项目(2022JBGS041-9,2022JBGS041-10)。

摘　　要：为提高汽车差速器壳的生产性能,同时减少加工工序和材料浪费,设计了一套镦粗、预锻、终锻及冲孔的多工位连续成形方案,并通过Deform-3D软件进行了模拟实验。首先,研究了生产材料40Cr合金钢在高温条件下的塑性流动行为,并拟合得到了用于模拟的本构方程,确保了实验结果的可靠性。其次,探究了不同预锻方案对成形结果的影响并评判了各方案的可行性,对比分析了成形过程中的金属流动规律、载荷变化规律和锻件温度分布规律等重要指标,同时研究了锻模材料SKD61钢在高温条件下的磨损性能,并对Archard模型进行了修正,从而准确预测了各方案下的锻模磨损规律。最后,根据优选结果进行了差速器壳的多工位锻造实验,实验过程顺利,制得的差速器壳质量较好,表面及内部均不存在缺陷,与模拟结果完全相符,可以代替当前落后的生产工艺。In order to improve the production performance of an automotive differential housing and reduce the processing procedures and material waste,a multi-station continuous forming scheme for upsetting,pre-forging,final forging and punching was designed,and the simulation experiments were conducted by Deform-3D software.First,the plastic flow behavior of production material of 40Cr alloy steel at high temperature was studied,and the constitutive equation for simulation was obtained to ensure the reliability of the test results.Then,the influences of different pre-forging schemes on the forming results were studied,the feasibility of each scheme was evaluated,and the important indicators such as metal flow law,load change law and forging temperature distribution law during the forming process were compared and analyzed.Meanwhile,the wear performance of forging die steel SKD61 under high temperature condition was studied,and the Archard model was modified to accurately predict the wear law of forging die for each scheme.Finally,according to the optimal results,the multi-station forging test of differential housing was conducted,and the test process was smooth.The results show that the quality of the produced differential housing is good,and there are no defects on the surface and inside,which is completely consistent with the simulation results and can replace the current outdated production process.

关 键 词：差速器壳 多工位连续成形 金属流动 载荷变化 温度分布 锻模磨损 

分 类 号：TG316.3[金属学及工艺—金属压力加工]