【摘要】：在汽車制造技術迅猛發(fā)展的今天,各大汽車廠商不僅僅在整車性能上進行激烈的競爭,在汽車零部件生產上的競爭也日趨激烈,包括新材料的應用、新的成形工藝的研發(fā),這些方面都備受業(yè)內關注。其中,與驅動橋殼相連接的半軸套管是主要的、必不可少的零件,承受著整車的全部重量,并且在汽車行駛的過程中,承受著復雜的交變應力,所以說半軸套管的質量是否過關與乘客的生命財產安全息息相關。現(xiàn)在半軸套管的成形技術雖然已經很成熟了,但是普遍采用的成形方案是以棒材為原材料,然后進行多工步成形。這樣的成形方案不僅材料利用率低,而且由于工步多,嚴重影響生產效率,增大了制造誤差,造成廢品率很高。為了徹底解決以上缺陷,各大廠家積極研發(fā)最新的成形工藝,以用來降低成本,以能夠適應目前的競爭激烈的汽車零部件市場。所以吉林大學作為汽車行業(yè)研發(fā)的先鋒,提出了以管坯為原材料的一次鐓擠成形工藝。本文通過認真分析現(xiàn)有的半軸套管的成形方案,大膽提出了以管坯為原材料的一次鐓擠成形工藝,徹底的摒棄了以往的繁瑣工序,效率得到大大提高,成本顯著降低。一旦實現(xiàn)量產,前景不可估量。本文針對半軸套管新的成形工藝主要對以下幾個方面的內容進行了研究:(1)本文根據管材成形的相關理論及半軸套管的幾何形狀特征,設計了半軸套管鍛件圖,并通過后期的有限元仿真模擬及實驗,驗證了鍛件圖的合理性。依據金屬塑性成形前后體積相等的原則及所設計的鍛件圖,詳細計算了管坯的尺寸。最終確定了以管坯為原材料的一次鐓擠成形工藝。(2)利用成形軟件DEFORM-3D進行有限元仿真模擬,不僅能夠驗證前邊設計的鍛件圖的合理性,又通過對半軸套管成形結果的詳細的分析,論證了以管材為原材料的一次鐓擠成形半軸套管的合理性。并且利用正交試驗,通過對幾個重要的影響參數(shù)的優(yōu)化,探討了各個影響參數(shù)對成形結果影響的大小,并且找到了使得成形載荷最小的工藝參數(shù)組合。(3)由于本文中采用的是臥式液壓鐓鍛機成形半軸套管,無先例可以參考,所以設計模具時帶來了很大的困難,從多種方案中優(yōu)選以后,采用了本文所設計的模具結構,凹模分為上下凹模,利用垂直液壓缸帶動上凹模進行上下行進,用來與下凹模進行開合。其中凹模又創(chuàng)新性的采用了鑲塊結構,壓緊鑲塊與成形鑲塊分割開來,有利于模具的更換。在水平方向上,凸模在液壓缸的帶動下對管坯進行鐓擠。(4)針對現(xiàn)有的臥式液壓鐓鍛機進行了詳細的理論分析,證明了其能夠滿足本文中半軸套管的成形。(5)針對以上的研究內容,在車橋廠進行了樣件的試制,驗證了以上研究內容的合理性。(6)從工程應用價值方面進行分析,證明了本文所研究的成形工藝能夠達到高效、經濟、環(huán)保的效果。
[Abstract]:Today, with the rapid development of automobile manufacturing technology, the major automobile manufacturers are not only engaged in fierce competition in vehicle performance, but also in the production of automotive parts, including the application of new materials and the research and development of new forming technology. These aspects have attracted the attention of the industry. Among them, the half axle casing connected with the drive axle housing is the main and essential part, bearing the full weight of the whole vehicle, and the complex alternating stress in the driving process of the vehicle. Therefore, the quality of half-shaft casing is closely related to the safety of passengers' lives and property. Although the forming technology of half shaft casing is very mature, the commonly used forming method is to take bar as raw material and then multiplex forming. Not only the material utilization ratio is low, but also the production efficiency is seriously affected, the manufacturing error is increased, and the scrap rate is very high. In order to completely solve the above defects, the major manufacturers actively develop the latest forming process to reduce costs, in order to adapt to the current fierce competition in the automotive parts market. Therefore, Jilin University, as the pioneer of automobile research and development, put forward a upsetting extrusion process with tube billet as raw material. In this paper, by analyzing the existing forming scheme of half-shaft casing, a new upsetting and extrusion process with tube billet as raw material is put forward, which completely abandons the previous complicated working procedure and greatly improves the efficiency and reduces the cost significantly. Once mass production is realized, the prospect is incalculable. The following aspects are studied in this paper: (1) according to the theory of tube forming and the geometry characteristics of half shaft casing, the forging drawing of half shaft casing is designed in this paper. The rationality of forging drawing is verified by finite element simulation and experiment. According to the principle of equal volume before and after metal plastic forming and the design of forging drawing, the size of tube blank is calculated in detail. Finally, the process of upsetting extrusion with tube billet as raw material is determined. (2) finite element simulation is carried out by means of forming software DEFORM-3D, which can not only verify the rationality of the forging drawing designed in front, Through the detailed analysis of the forming results of half-shaft casing, the rationality of one-stage upsetting forming casing with pipe as raw material is demonstrated. By using orthogonal test and optimization of several important influence parameters, the influence of each parameter on the forming result is discussed. And found the process parameters to minimize the forming load. (3) because the horizontal hydraulic upsetting machine is used in this paper to form the half shaft casing, there is no precedent to refer to, so the design of the die has brought great difficulties. After the best selection of various schemes, the die structure designed in this paper is adopted. The concave die is divided into upper and lower concave die, and the vertical hydraulic cylinder is used to drive the upper concave die up and down, which is used to open and close with the lower concave die. The die adopts the inlay structure innovatively, and the compaction block is separated from the forming block, which is advantageous to the replacement of the die. In the horizontal direction, the punch is driven by the hydraulic cylinder to upsetting and extruding the tube billet. (4) the theoretical analysis of the existing horizontal hydraulic upsetting forging machine is carried out in detail. It is proved that it can satisfy the forming of the middle axle casing in this paper. (5) in view of the above research content, the prototype is made in the vehicle bridge factory, and the rationality of the above research content is verified. (6) the engineering application value is analyzed. It is proved that the forming process studied in this paper can achieve the effect of high efficiency, economy and environmental protection.
【學位授予單位】：吉林大學
【學位級別】：碩士
【學位授予年份】：2016
【分類號】：U466

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