轿车轮毂轴承铆装工艺理论分析与试验研究

摘要/Abstract

摘要： 对轿车轮毂轴承单元的铆装工艺进行了理论分析和试验研究。建立了铆装力理论计算模型与铆装工艺有限元分析模型，研究了铆头轨迹、倾角和停留时间等工艺参数对铆装质量的影响，得出采用圆周轨迹、铆头倾角6°和停留时间0.8s时铆装质量最好的结论。以DAC2F10轿车轮毂轴承单元为例，在课题组开发的铆合装配专用机床上进行了铆装试验，验证了铆装力理论模型和铆装工艺有限元模型的合理性，并进一步优化铆头倾角为5.5°。采用所优化的铆装工艺试制出了轮毂轴承单元样件，耐久性试验测试最高使用寿命近2×105km，表明得出的铆装优化工艺能大幅提高轮毂轴承单元的使用寿命和可靠性。

关键词: 轮毂轴承, 摆动碾压, 铆合装配, 工艺参数, 使用寿命

Abstract: The theoretical analyses and experimental study for riveting and assembly processes of automotive hub bearing units were conducted. The theoretical calculation model of riveting and assembly forces and the finite element analysis model of riveting and assembly processes were established to study the effects of trajectories, inclination angles and duration times of the final riveting phase of the rivet head on riveting and assembly quality. The results show the riveting and assembly quality is optimal under processing parameters including a circumference trace, an inclination angle of 6° and a final riveting duration time of 0.8s of a rivet heat. Taking DAC2F10 automotive hub bearing unit as an example, it was assembled by the special machine tool developed by authors for riveting and assembly. The experiments show the theoretical calculation model of riveting and assembly forces and the finite element analysis model of riveting and assembly processees are rational. And the inclination angle of rivet head is optimized as 5.5°. The prototype automotive hub bearing unit is manufactured by the optimized riveting and assembly processes and the maximum service life examined by durability tests is nearly 200 000km, which shows the optimized riveting and assembly processes herein may greatly enhance the working life and reliability of automotive hub bearing units.

Key words: hub bearing, rotary forging, riveting assembly, processing parameter, service life

中图分类号:

TG306

杨军1;杨允松1;李伟1;肖耘亚2;周志雄1. 轿车轮毂轴承铆装工艺理论分析与试验研究[J]. 中国机械工程.

YANG Jun1;YANG Yunsong1;LI Wei1;XIAO Yunya2;ZHOU Zhixiong1. Theoretical Analyses and Experimental Studies for Riveting and Assembly Processes of Automotive Hub Bearing Units[J]. China Mechanical Engineering.

参考文献

[1]SAKAMOTO J. Trends and New Technologies of Hub Unit Bearings[J]. NSK Motion & Control, 2005，17: 2-9.
[2]肖耘亚. 轿车轮毂轴承单元摆碾铆合装配新工艺及设备的研究[D]. 长沙: 湖南大学, 2014.
XIAO Yunya. Research on New Process and Equipment for Precision Riveting and Assembly of Automotive Hub Bearing Units [D]. Changsha: Hunan University, 2014.
[3]ISHIDA H, KANEKO T. Development of Hub Unit Bearing with Swaging[J]. NSK Motion & Control, 2001，10: 9-14.
[4]KAJIHARA K.Improvement of Simulation Technology for Analysis of Hub Unit Bearing [J]. Koyo Engineering Journal English Edition, 2005，167E: 35-39.
[5]MOON H K, LEE M C, JOUN M S. An Approximate Efficient Finite Element Approach to Simulating a Rotary Forming Process and Its Application to a Wheel-bearing Assembly[J]. Finite Elements in Analysis and Design, 2007,44: 17-23.
[6]HYUNJIK C, JEONGSEO K. Orbital Forming Simulation of Automotive Hub Bearing Using the Explicit Finite Element Method[J]. International Journal of Modern Physics B, 2008, 22(9/11): 1626-1633.
[7]CHO H J, KOO J S, BAE W R, et al. A Study on Orbital Forming Analysis of Automotive Hub Bearing Using the Explicit Finite Element Method[J]. Transactions of the Korean Society of Automotive Engineers, 2008, 16(1): 29-36.
[8]WU Jia, LU Xiong. Load Analysis of Wheel Hub Bearing in Wheel Driving System with Exterior Rotor Motor[J]. Advanced Materials Research, 2012, 479/481, 670-675.
[9]汪浔. 基于CAE 的轿车轮毂轴承单元刚性分析及试验研究[D]. 广州: 华南理工大学, 2011.
WANG Xun. Moment Rigidity Analysis on Whole Automotive Hub Unit Bearing Based on CAE and Its Research on Experiment[D]. Guangzhou: South China University of Technology, 2011.
[10]卢小辉. 基于遗传算法的轿车轮毂轴承单元法兰盘轮毂优化设计[D]. 广州: 华南理工大学, 2011.
LU Xiaohui. Optimization Design on Hub Flange of Hub Unit Bearing Based on Genetic Algorithm[D]. Guangzhou: South China University of Technology, 2011.
[11]杨林. 汽车轮毂轴承早期失效分析及试验研究[D]. 广州: 华南理工大学, 2012.
YANG Lin. Early Failure Analysis & Experimental Research of Automobile Wheel Hub Bearing[D]. Guangzhou: South China University of Technology, 2011.
[12]张吉健. 汽车轮毂轴承的可靠性建模与试验技术研究[D]. 杭州: 浙江工业大学, 2009.
ZHANG Jijian. Study on Modeling Technique and Improving Reliability of Automobile Hub-bearing[D]. Hangzhou: Zhejiang University of Technology, 2009.
[13]王露. 轮毂轴承多工况疲劳寿命建模与数值仿真[D]. 杭州: 浙江工业大学, 2009.
WANG Lu. Modeling & Numerical Simulation of Fatigue Lifeof Hub Bearing Based on Multi-bench Test Load[D]. Hangzhou: Zhejiang University of Technology, 2009.
[14]黎桂华. 轴向游隙对轿车轮毂轴承性能的影响[J]. 轴承, 2011(1): 1-3.
LI Guihua. Effect of Axial Clearance on Performances of Car Hub Bearings[J]. Bearing, 2011(1): 1-3.
[15]尹治国. 汽车轮毂轴承单元轴铆合过程仿真分析[D]. 广州: 华南理工大学, 2012.
YIN Zhiguo. CAE Analysis of Automotive Hub Unit Bearing Shaft-end Clinching Procedure[D]. Guangzhou: South China University of Technology, 2012.
[16]张猛. 环形件摆动辗压力计算[J]. 热加工工艺, 1988(3): 15-21.
ZHANG Meng.Calculating Force in Rotary Forging Rings[J]. Hot Working Technology, 1988(3): 15-21.
[17]伍太宾, 胡亚民. 冷摆辗精密成形[M]. 北京：机械工业出版社, 2011: 34-35.
WU Taibin, HU Yamin. Precision Forming of Cold Rotary Forging[M]. Beijing: Mechanical Industry Press, 2011: 34-39.
[18]马俊林, 高仕恒, 李萍,等. 一种新型Al-Zn-Mg-Cu合金杯形件摆辗成形数值模拟及实验研究[J]. 中国机械工程, 2016, 27(7): 970-975.
MA Junlin, GAO Shiheng, LI Ping, et al. Numerical Simulation and Experimental Study on Rotary Roll Forging for a New Al-Zn-Mg-Cu Alloy Cup[J]. China Mechanical Engineering, 2016, 27(7): 970-975.
[19]党玉功, 邓效忠, 王斌,等. 准双曲面齿轮冷摆辗加工新方法及其数值模拟[J]. 中国机械工程, 2014, 25(9): 1250-1255.
DANG Yugong, DENG Xiaozhong, WANG Bin, et al. A New Type Cold Rotary Forging Method for Hypoid Gear and Its Numerical Simulation[J]. China Mechanical Engineering, 2014, 25(9): 1250-1255.