锻压技术

同轴式电动汽车带轴头桥壳的一体式成形工艺

英文标题：Integral forming process on coaxial electric vehicles with axle head axle housing

单位：1.燕山大学车辆与能源学院 2.长城汽车股份有限公司 3.秦皇岛通桥科技有限公司 4.中信戴卡股份有限公司

分类号：TG316

出版年,卷(期):页码：2022,47(12):94-102

摘要：

针对同轴式电动汽车驱动桥，设计了带轴头桥壳的一体式成形工艺，首先选用无缝钢管进行胀压成形制得预成形管坯，再对两端圆管部分进行冷态缩径、热态挤压成形轴头及与内侧连接的台肩。建立轴头挤压成形的力学模型，分析金属的流动趋势，揭示挤压量、镦粗区加热长度对轴头、台肩成形的影响规律，并给出挤压量的近似计算公式。针对某轴荷80 kN的电动汽车桥壳，通过有限元模拟和1∶1工程试验，揭示了挤压量s、镦粗区加热长度L对台肩根部壁厚、内腔圆角半径的影响规律，确定了s的合适范围为36~39 mm、L的合适范围为34~44 mm。研究表明：设计的一体式成形工艺可行，为生产实践提供了重要依据。

For the drive axle housing of coaxial electric vehicle, the integral forming process with axle head axle housing was designed. First, the seamless steel tube was firstly expanded and pressed to make a preformed tube blank, and then the circular tubes at both ends were cold-reduced, hot extruded to form shaft head and shoulder connected to the inner side. Furthermore, the mechanical model of shaft head extrusion forming was established, the flow trend of metal was analyzed, the influence laws of extrusion quantity and heating length of upsetting area on the formation of shaft head and shoulder were revealed, and the approximate calculation formula of extrusion quantity was given. For an axle hosing of electric vehicle with axle load of 80 kN, the influence laws of extrusion quantity s and heating length L of upsetting area on the thickness of root for the shoulder and the fillet radius of the inner cavity were revealed by the finite element analysis and 1∶1 engineering tests, and the suitable range of s and L was 36-39 mm and 34-44 mm, respectively. The results show that the designed integral forming process is feasible, and provides the important evidence for production practice

基金项目：

河北省重大科技成果转化专项资助项目（20282202Z）

王连东（1967-），男，博士，教授，博士生导师 E-mail：wld670509@163.com

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