充液压制成形汽车桥壳后盖区开裂分析及预成形管坯形状优化设计

摘要/Abstract

摘要： 针对目前生产中胀压成形桥壳后盖区存在开裂的现象，通过对两种极端情况下预成形管坯压制成形变形的分析，揭示了后盖区开裂的原因；提出了预成形管坯后盖冠顶最大纵向轮廓形状的设计方法，给出了轮廓基准系数K0和渐变系数K1的定义。针对某载重5t的汽车桥壳，采用ABAQUS有限元分析软件对多组不同后盖尺寸的预成形管坯压制成形过程进行了数值模拟，确定了轮廓基准系数K0和渐变系数K1的取值范围。进行了压制成形实验，结果表明：优化设计后的预成形管坯充液压制时成形效果好，后盖区壁厚减薄率低、无开裂。

关键词: 汽车桥壳, 胀压成形, 预成形管坯, 开裂, 有限元模拟

Abstract: Aiming at the phenomenon of rear cover cracking in current production, the cracking reason was revealed by analyzing the pressing deformation of rear covers in two extreme cases. The design method of the maximum longitudinal section profile of the preformed pipes was proposed, and the definitions of the profile reference coefficient K0 and gradient coefficient K1 were given. For a 5t automobile axle-housing, the value ranged of the profile reference coefficient K0 and gradient coefficient K1 were determined through simulating the pressing forming processes of the preformed pipes with different sizes of rear covers using ABAQUS. And the results of the pressing forming test show that the optimized pipes are of good formability, the wall thinning rate of rear covers is low and there is no cracking.

Key words: axle housing, bugling-pressing forming, preformed pipe, cracking, finite element simulation

中图分类号:

TG316

吴娜, 王连东, 沈亚坤, 张蒙. 充液压制成形汽车桥壳后盖区开裂分析及预成形管坯形状优化设计[J]. 中国机械工程.

Wu Na, Wang Liandong, Shen Yakun, Zhang Meng. Cracking Analysis of Rear Covers and Shape Optimization of Preformed Pipes for Filling-pressing Forming Axle Housings[J]. China Mechanical Engineering.

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