锻压技术

三维轴线后副车架纵梁内高压成形工艺

英文标题：Hydroforming process on three-dimensional axis side-beam of rear subframe

作者：王娜

分类号：TG394

出版年,卷(期):页码：2021,46(4):121-126

摘要：

利用非线性有限元分析软件AutoForm，对三维轴线的底盘后副车架纵梁进行弯管、预成形、内高压成形的全过程分析，根据零件非对称和不等截面的几何特征，确定零件工艺参数和加载路径，并分析预成形过程中的零件表面拉毛缺陷。同时，针对不同壁厚（4.0和4.5 mm）的纵梁管坯，通过采用相同的工装模具和不同的内高压成形工艺参数，验证了内高压成形零件型面的一致性。结果显示：壁厚为4.0和4.5 mm的纵梁分别经170和200 MPa的内压力，得到的纵梁零件型面差异最大为±0.3 mm，型面一致性较好。通过对预成形镶块进行渗氮+PVD的表面处理试验后，镶块表面硬度达到3000 HV以上，降低了摩擦系数，有效解决了零件的外观拉毛问题，改善了纵梁零件的表面质量，最终通过试验验证了采用内高压成形工艺制造三维轴线纵梁零件的可行性。

The whole process of tube bending, pre-forming and hydroforming of three-dimensional axis side-beam for rear subframe was analyzed by the nonlinear finite element analysis software AutoForm. Then, according to the geometric characteristics of part with asymmetric and unequal sections, the process parameters and loading path of part were determined, and the surface roughness defects of part during the pre-forming process were analyzed. At the same time, for the side-beam tube blanks with the wall thicknesses of 4.0 and 4.5 mm respectively, the consistency of hydroforming part profile was studied by the same tooling and die and different hydroforming process parameters. The results show that the maximum profile difference of side-beam part with the wall thicknesses of 4.0 and 4.5 mm under the internal pressures of 170 and 200 MPa respectively is ±0.3 mm, and the profile consistency is good. After the surface treatment test of nitriding and PVD on the pre-formed inserts, the surface hardness of inserts reaches more than 3000 HV, the friction coefficient reduces. The problem of rough appearance of part is solved effectively, and the surface quality of side-beam part is improved. Finally, the feasibility of using hydroforming technology to manufacture the three-dimensional axis side-beam is verified by experiments.

基金项目：

王娜（1979-），女，博士，工程师 E-mail：wangna@baosteel.com

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