电控差速锁壳体热锻工艺方案设计与优化  

Design and Optimization of Hot Forging Process for Electronically Controlled Differential Lock Shell

作　　者：王敏 李旭辉[1,2,3,4] 陈天赋 李航 陈荣创 张春 SHORNA Sharmin Jahan WANG Min;LI Xuhui;CHEN Tianfu;LI Hang;CHEN Rongchuang;ZHANG Chun;SHORNA Sharmin Jahan(College of Materials Science and Engineering,Hubei Shiyan 442002,China;Hubei Key Laboratory of Energy Storage and Power Battery,Hubei Shiyan 442002,China;Hubei Key Laboratory of Automotive Power Train and Electronics,Hubei University of Automotive Technology,Hubei Shiyan 442002,China;Hubei Longzhong Laboratory,Hubei Xiangyang 441000,China;Hubei Triring Forging Co.,Ltd.,Hubei Xiangyang 441700,China)

机构地区：[1]湖北汽车工业学院材料科学与工程学院,湖北十堰442002 [2]湖北汽车工业学院储能与动力电池湖北省重点实验室,湖北十堰442002 [3]湖北汽车工业学院汽车动力传动与电子控制湖北省重点实验室,湖北十堰442002 [4]湖北隆中实验室,湖北襄阳441000 [5]湖北三环锻造有限公司,湖北襄阳441700

出　　处：《精密成形工程》2024年第12期264-273,共10页Journal of Netshape Forming Engineering

基　　金：湖北省自然科学基金(2024AFD099);湖北隆中实验室自主创新项目(2022ZZ-30);湖北省高等学校优秀中青年科技创新团队计划(T201518);储能与动力电池湖北省重点实验室开放基金(ZDK22023B08,QCCLSZK2021B03,QCCLSZK2021B06)。

摘　　要：目的通过对电控差速锁壳体热锻工艺方案进行优化,解决因其形状复杂而导致的填充不满、折叠等锻造缺陷问题。方法依据壳体的结构特征,设计了3种闭式热模锻工艺方案。建立了壳体热锻过程热力耦合有限元模型及模具应力分析数值模型。利用该模型对3种模锻工艺方案进行模拟,并通过对模拟结果的对比分析,获得了优化工艺方案。结果通过对3种工艺方案进行模拟分析,发现在镦粗方案和缩颈方案下金属能够完整填充终锻模具型腔,而小孔方案在终锻中出现了空穴-回填现象,可能导致折叠的产生,因此对镦粗方案和缩颈方案做进一步对比。通过对这2种方案在成形载荷、锻件温度/应变、模具应力以及坯料体积等方面的对比研究,发现与缩颈方案相比,虽然镦粗方案的坯料体积略大,但是锻件温度范围和分布更合理,制坯和终锻工序的锻件应变较小,制坯和预锻工序的最大模具应力较小。结论通过综合对比分析,确定镦粗方案为优化方案。采用壳体热锻实验,从锻件外形、微观组织和硬度等方面验证了该优化方案的有效性。The work aims to optimize the hot forging process scheme for the electronically controlled differential lock shell,to solve the problems such as underfilling,folding and other forging defects caused by its complex shape.Based on the structural characteristics of the shell,three closed hot-die forging process schemes were designed,and a thermodynamic coupling finite element model for hot forging process of the shell and a numerical model for die stress analysis were established.The models were used to simulate the three die forging process schemes,and the optimized process scheme was obtained through the comparative analysis of the simulation results.Through the simulation analysis of the three process schemes,it was found that the metal was able to fill the final forging die cavity completely under the upsetting scheme and the shrinkage scheme,while the small hole scheme showed a cavity-backfill phenomenon in the final forging,which might lead to the generation of folding,so only the upsetting scheme and the shrinkage scheme were further compared.Through the comparative study of the two schemes in terms of forming load,forging temperature/strain,die stress and billet volume,it was found that the billet volume of the upsetting scheme was slightly larger than that of the shrinkage scheme,but the temperature range and distribution of the forging were more reasonable,the forging strains in the billet making and final forging processes were smaller,and the maximum die stresses in the billet making and pre-forging processes were also smaller.Through comprehensive comparative analysis,the upsetting scheme is determined as the optimized scheme.Through the hot forging experiment of shell,the effectiveness of the optimized scheme is verified from the aspects of forging shape,microstructure and hardness.

关 键 词：壳体 闭式热模锻 工艺方案 优化 有限元模拟 

分 类 号：TG156.3[金属学及工艺—热处理] TG306[金属学及工艺—金属学]