车辆自动变速器齿形离合器毂冲挤塑性变形过程的数值模拟研究
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摘要
汽车齿形离合器毂是自动变速器内技术难度较高的零件之一,随着汽车轻量化、高强度和低成本化的发展,近年来该部件纷纷以金属板材体积成形方式加工。本文应用有限元仿真软件DEFORM-3D对离合器毂齿形冲挤成形过程进行数值模拟,分析冲挤过程中齿形成形过程中的应力场和流动行为,并对比不同壁厚、不同直径坯料和不同摩擦系数下齿形的填充效果和成形力大小。仿真结果显示,变形区主要剪应变,材料在圆弧处流动较差,初始板材厚度的增加对成形精度提高十分有利,同时也导致成形力的剧烈上升,摩擦系数越小成形精度越高,成形力也越小,而坯料内径大小对成形精度和成形力均无明显影响。
The automotive gear clutch hub is one of the technically difficult parts in automatic transmissions.With the development of lightweight, high-strength and low-cost automobiles, this component has been pro-cessed in recent years in the form of sheet metal forming. The finite element simulation software DEFORM-3 D has been used to simulate the tooth profile forming process of the clutch hub in the text. The stress field and flow behavior of the tooth forming process during the extrusion process have been analyzed, while the filling effect of the tooth shape and the size of the forming force have been compared under different wall thicknesses, billets with different diameters and different friction coefficient. The simulation results show that the main deformation zone is shear strain, and the material flow is poor at the arc; the increase in the initial thickness of the plate is very beneficial to improve the forming accuracy, which also leads to a sharp increase in forming force; the smaller the friction coefficient is, the higher the forming accuracy is while the smaller the forming force is; the size of the inner diameter of the blank has no significant effect on the forming accuracy and forming force.
The automotive gear clutch hub is one of the technically difficult parts in automatic transmissions.With the development of lightweight, high-strength and low-cost automobiles, this component has been pro-cessed in recent years in the form of sheet metal forming. The finite element simulation software DEFORM-3 D has been used to simulate the tooth profile forming process of the clutch hub in the text. The stress field and flow behavior of the tooth forming process during the extrusion process have been analyzed, while the filling effect of the tooth shape and the size of the forming force have been compared under different wall thicknesses, billets with different diameters and different friction coefficient. The simulation results show that the main deformation zone is shear strain, and the material flow is poor at the arc; the increase in the initial thickness of the plate is very beneficial to improve the forming accuracy, which also leads to a sharp increase in forming force; the smaller the friction coefficient is, the higher the forming accuracy is while the smaller the forming force is; the size of the inner diameter of the blank has no significant effect on the forming accuracy and forming force.
引文
[1]智研咨询集团.2017-2022年中国汽车自动变速器行业尺长运营态势及发展前景预测[R].北京,2016.
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[3]Merklein M,Allwood J M,Behrens B A,et al.Bulk forming of sheet metal[J].CIRP Annals-Manufacturing Technology,2012,61(2):725-745.
[4]http://www.ernst-grob.com/en/processes/cold-forming-sheet-metal
[5]范酉根,吴延昭,韩荣玲,等.变速器外毂件齿形强力旋压成形研究[J].锻压技术,2015,(10).
[6]Ko D H,Lee S K,Kwon Y N,et al.Improvement in dimensional accuracy of roll-die-formed clutch hub used in automotive transmission[J].International Journal of Precision Engineering&Manufacturing,2012,13(2):237-243.
[7]Zhuang X,Sun X,Xiang H,et al.Compound deep drawing and extrusion process for the manufacture of geared drum[J].International Journal of Advanced Manufacturing Technology,2016.
[8]魏雅新,陈泽中.齿形离合器毂冲挤复合成形工艺[J].塑性工程学报,2016,23(1):16-20.
[9]Osakada K,Mori K,Altan T,et al.Mechanical servo press technology for metal forming[J].CIRP Annals-Manufacturing Technology,2011,60(2):651-672.
[10]Meng D,Zhao S,Li L,et al.A servo-motor driven active blank holder control system for deep drawing process[J].International Journal of Advanced Manufacturing Technology,2016,87(9-12):3185-3193.
[11]杨合,詹梅.材料加工过程实验建模方法[M].西安:西北工业大学出版社,2008.
[2]黄宗益.现代轿车自动变速器原理和设计[M].上海:同济大学出版社,2006.
[3]Merklein M,Allwood J M,Behrens B A,et al.Bulk forming of sheet metal[J].CIRP Annals-Manufacturing Technology,2012,61(2):725-745.
[4]http://www.ernst-grob.com/en/processes/cold-forming-sheet-metal
[5]范酉根,吴延昭,韩荣玲,等.变速器外毂件齿形强力旋压成形研究[J].锻压技术,2015,(10).
[6]Ko D H,Lee S K,Kwon Y N,et al.Improvement in dimensional accuracy of roll-die-formed clutch hub used in automotive transmission[J].International Journal of Precision Engineering&Manufacturing,2012,13(2):237-243.
[7]Zhuang X,Sun X,Xiang H,et al.Compound deep drawing and extrusion process for the manufacture of geared drum[J].International Journal of Advanced Manufacturing Technology,2016.
[8]魏雅新,陈泽中.齿形离合器毂冲挤复合成形工艺[J].塑性工程学报,2016,23(1):16-20.
[9]Osakada K,Mori K,Altan T,et al.Mechanical servo press technology for metal forming[J].CIRP Annals-Manufacturing Technology,2011,60(2):651-672.
[10]Meng D,Zhao S,Li L,et al.A servo-motor driven active blank holder control system for deep drawing process[J].International Journal of Advanced Manufacturing Technology,2016,87(9-12):3185-3193.
[11]杨合,詹梅.材料加工过程实验建模方法[M].西安:西北工业大学出版社,2008.