Abstract:  A finite element predictive approach involving severe plastic deformation of the materials and including three subsequent models（knurling， press-fit and torsion strength） were established  based on the coupled Euler-Lagrangian mesh and Johnson-Cook material model. The sub models were connected in series by transferring the residual stress and strain fields of the shaft tubes to ensure the continuity of the physical fields. The whole process of radial knurling assembly was systematically simulated by connecting each working step model in series； the press-fit force， static torsional strength and the variation characteristics of the cam profiles were predicted and analyzed. The influence law of knurling tool parameters and feed rate on the press-fit force and static torsional strength was revealed. It is shown that numerical results of morphological characteristics of shaft tubes in knurling and assembly area as well as temperature field are in good agreement with the experimental work. The torque strength of the joint is 90% higher than that of a typical passenger vehicle requirement. The torque strength is significantly positive correlated to the press-fit loads. The max displacement of outline of cam is not less than 0.0425 mm. The predicted press-fit and joining strength using the subsequent modeling are validated by the experimental measurement with maximum errors less than 11%. The subsequent models may partly take a place of knurling assembly tests， which is instrumental in shorten development cycles. 

Key words: assembled camshaft, mechanism of radial knurling joint, press-fit force, static torsional strength, cam contour accuracy, residual stress

摘要： 基于耦合的欧拉-拉格朗日网格及Johnson-Cook材料模型，建立了涉及局部大变形的组合式凸轮轴径向滚花、压装及扭转子模型。各子模型间通过传递轴管的残余应力应变场实现相互串联，保证物理场的连续性，系统地模拟径向滚花装配全流程。预测并分析了压装力、静扭强度及凸轮型线的变化特征，揭示了滚花刀参数及进给量对压装力及静扭强度的影响规律，并结合试验验证了模拟结果的可靠性。结果表明，滚花和装配区域轴管形貌特征及温度场的模拟结果与试验结果高度吻合。典型装配参数下，静扭强度超过乘用车发动机凸轮轴标准静扭强度的90%，静扭强度与装配压装力成正比，凸轮型线最大位移为0.0425 mm。子模型预测各因素值与试验值的误差均小于11%，可在一定程度上代替不同型号凸轮轴的装配试验，缩短研制周期。

关键词: 组合式凸轮轴, 径向滚花装配机理, 压装力, 静扭强度, 凸轮外轮廓精度, 残余应力