锻压技术

汽车传动轴轴套的近净成形工艺研究与应用

英文标题：Research and application on near net forming process for automobile transmission shaft bushing

作者：高琳1 史海红2 任燕3

分类号：TG316.3

出版年,卷(期):页码：2023,48(9):23-31

摘要：

为解决一种汽车传动轴轴套切削加工生产效率低、成本高的问题，根据其结构特点并基于塑性成形理论设计了两种全新的加工工艺，即先通过冷镦加工制坯，后经少量切削完成最终成形，可使材料利用率从26.9%提高至86.1%。利用有限元软件Deform3D对这两种工艺的冷镦部分进行成形模拟，评估了两种工艺的可行性，并对两种工艺各工位的等效应力、成形力、损伤值等进行了对比。结果表明：两种工艺均能满足成形需求，获得预期的制坯件，并且采用方案2时，等效应力和损伤值分布更好，同时所需成形力更小，利于提高制坯件质量和降低模具冲击。最后，将方案2应用于轴套的加工，完成了生产试验，最终得到的制坯件成形较好，无缺陷，与模拟结果一致，经最终少量切削后，轴套尺寸完全符合需求，与之前工艺相比，效率和成本均得到明显改善。

In order to solve the problems of low production efficiency and high cost in the cutting of an automobile transmission shaft bushing, two new machining processes were designed according to its structural characteristics and plastic forming theory, namely, the billet was made by cold heading firstly, and then the final forming was completed by a small amount of cutting, which increased the material utilization rate from 26.9% to 86.1%. Then, the forming of the cold heading part for the two processes was simulated by finite element software Deform-3D, respectively, the feasibility of the two processes was evaluated, and the equivalent stress, forming force and damage value of each station for the two processes were compared. The results show that the two processes can meet the forming requirements and obtain the expected billet parts. When the scheme 2 is adopted, the distributions of equivalent stress and damage values are better and the required forming force is smaller, which is beneficial to improve the quality of billet part and reduce the mold shock. Finally, the scheme 2 was applied to the machining of the shaft bushing, and production experiments were completed. The final billet part is well formed without defects, which is similar to the simulation results. After a small amount of final cutting, the size of shaft bushing fully meets the requirements, and compared with the previous process, the efficiency and cost are significantly improved.

基金项目：

河南省高等学校重点科研项目（23B460027）

作者简介：高琳（1975-），女，学士，高级讲师 E-mail：gaolin19750@126.com

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