轻卡变速箱薄壁端盖铣削加工有限元仿真分析  

Finite Element Simulation Analysis on Milling Process of Thin-Walled End Cover of Light Truck Gearbox

作　　者：王海盈 万一品 霍亚光[2] 李培超 WANG Hai-ying;WAN Yi-pin;HUO Ya-guang;LI Pei-chao(School of Engineering Machinery,Chang′an University,Xi′an 710064,Shaanxi,China;Engineering Training Center,Chang′an University,Xi′an 710064,Shaanxi,China;Fast Eaton(Baoji)Light Transmission Co.,Ltd,Baoji 721001,Shaanxi,China)

机构地区：[1]长安大学工程机械学院,陕西西安710064 [2]长安大学工程训练中心,陕西西安710064 [3]法士特伊顿(宝鸡)轻型变速器有限责任公司,陕西宝鸡721001

出　　处：《机械研究与应用》2025年第2期122-124,共3页Mechanical Research & Application

摘　　要：轻卡变速箱端盖作为典型薄壁铸件,其加工方式以铣削为主。为了使端盖铣削加工后的平面度符合要求,需要准确获取铣削加工后端盖表面的残余应力。文章分别建立了变速箱端盖和硬质合金立铣刀的有限元模型,并基于HyperMesh软件和ABAQUS软件建立了铣削加工动态仿真模型,通过仿真来研究端盖铣削后表面残余应力的大小和分布规律。研究表明:刀具进给方向残余应力最大值为465 MPa,平均应力为156 MPa。沿着进给方向的工件铣削表面残余应力在550 mm附近达到最大值,随后呈现规律性分布;进刀槽残余应力最大值出现在端盖内部边缘,大小为458 MPa,应力由内到外逐渐减小;进刀槽纵向深度应力最大值出现在端盖表面,大小为436 MPa,应力沿着深度方向逐渐减小。所研究结果和结论为变速箱端盖铣削加工平面度的控制提供了有限元建模基础。As a typical thin-walled casting,the end cover of light truck gearbox is mainly processed by milling.In order to make the flatness of the end cover meet the requirements after milling,it is necessary to accurately obtain the residual stress on the surface of the end cover after milling.The finite element models of gearbox end cover and cemented carbide end mill are established respectively.Based on HyperMesh software and ABAQUS software,the dynamic simulation model of milling is established to study the size and distribution of residual stress on the surface of end cover after milling.The results show that the maximum residual stress in the feed direction of the tool is 465 MPa,and the average stress is 156 MPa.The residual stress of the workpiece milling surface along the feed direction reaches the maximum near 550 mm,and then shows a regular distribution.The maximum residual stress of the feed slot appears at the inner edge of the end cover is 458 MPa,and the stress gradually decreases from the inside to the outside.The maximum longitudinal depth of the feed slot appears on the surface of the end cover at 436 MPa,and the stress gradually decreases along the depth direction.The results and conclusions of this paper provide a finite element modeling basis for the flatness control of the gearbox end cover milling.

关 键 词：薄壁端盖 铣削加工 有限元仿真 残余应力 

分 类 号：TG54[金属学及工艺—金属切削加工及机床]