锻压技术

汽车变速器轴轻量化设计与旋转锻造仿真

英文标题：Lightweight design and rotary swaging simulation for automobile transmission shaft

作者：张琦田天泰张毓韩宾

单位：西安交通大学

分类号：U466；TG316

出版年,卷(期):页码：2023,48(5):266-274

摘要：

汽车零部件的轻量化设计与制造是助力整车轻量化、实现绿色制造和降低汽车碳排放的重要途径。以汽车变速器轴为对象，对其轻量化设计与高效精密制造进行了研究，基于Abaqus静力分析研究了相同静扭载荷下变速器轴不同空心轻量化设计时的应力分布，基于FORGE探究了变速器轴旋转锻造缩径过程的变形特征，实现了对设计管料的旋锻工艺验证。结果表明：空心设计能够很好地实现变速器轴的轻量化，结合变壁厚设计能够改善应力分布、提升轻量化水平至50%左右；使用旋转锻造工艺能够实现变速器轴的缩径和壁厚增厚，保证良好的精度，同时将成形损伤累积和成形力控制在较低水平。

The lightweight design and manufacturing of automobile parts is an important way to help vehicle lightweight, realize green manufacturing and reduce carbon emissions. Therefore, for the automobile transmission shaft, its lightweight design and efficient precision manufacturing were studied, and based on Abaqus static analysis, the stress distribution of transmission shaft with different hollow lightweight designs under the same static torsional load was studied. Furthermore, based on FORGE, the deformation characteristics of transmission shaft during the rotary swaging diameter reduction process were explored, and the rotary swaging process verification on the designed tube material was realized. The results show that the hollow design can well realize the lightweight of transmission shaft, and combined with the variable wall thickness design can improve the stress distribution and increase the lightweight level to about 50%. The use of rotary swaging process can reduce the diameter and thicken the wall thickness of transmission shaft, ensuring good accuracy while keeping forming damage accumulation and forming forces controlled at a low level.

基金项目：

国家自然科学基金资助项目（52275375）；陕西省重点研发计划（2021GXLH-Z-037）

作者简介：张琦（1978-），男，博士，教授,E-mail：henryzhang@mail.xjtu.edu.cn

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