锻压技术

汽车半轴精密成形工艺模拟及自动化生产线设计

英文标题：Simulation of precision forming process and design of automatic production line for automotive half shaft

作者：张培彦邹喆许文芳

单位：郑州旅游职业学院

分类号：TG316.3

出版年,卷(期):页码：2024,49(6):43-51

摘要：

针对汽车半轴摆辗成形工艺中存在的锻造缺陷问题，根据某型号汽车半轴的结构特点，提出一种新的汽车半轴精密成形工艺。首先，利用Gleeble-3500热模拟试验机对汽车半轴用42CrMo钢进行了高温压缩试验，得到其在不同变形条件下的真应力-真应变曲线。然后，将数据导入Defrom-3D材料库中，对汽车半轴的精密成形过程进行数值模拟，分析了成形过程中上模的载荷-时间曲线、工件的等效应力场分布、主要模具的应力分布、模具有无预热时工件的温度场分布等。并进行了相应的工艺试验，得到的预制坯锻件充填饱满，验证了提出的汽车半轴精密成形工艺的可形性。最后，根据有限元模拟和工艺试验得到的工艺参数，进行了汽车半轴锻造自动化生产线设计，对生产线布局和节拍进行了分析，实现了全流程自动化生产，达到降本增效的目的。研究结果对汽车半轴精密成形工艺及自动化生产具有一定的指导意义。

For the problem of forging defect existing in the swing rolling of automotive half shaft, a new precision forming process for automotive half shaft based on the structural characteristics of a certain model of automotive half shaft was proposed. Firstly, the high-temperature compression test was conducted on 42CrMo steel used for automotive half shaft by Gleeble-3500 thermal simulation test machine, and the true stress- true strain curves under different deformation conditions were obtained. Then, the data was imported into the Defrom-3D material library, and the numerical simulation analysis was conducted on the precision forming process of automotive half shaft to analyze the load-time curve of upper die during the forming process, the equivalent stress field distribution of workpiece, the stress distribution of main dies, and the temperature field distribution of workpiece with and without the preheating of dies. And corresponding process tests were conducted, and the obtainbed preformed blank forgings were fully filled, verifying the formability of the proposed precision forming process for automotive half shaft. Finally, based on the process parameters obtained from finite element simulation and process tests, an automatic forging production line for automotive half shaft was designed, and the layout and rhythm of the production line were analyzed, which achieved the whole flow of automatic production and the goal of cost reduction and efficiency increase.The study result has certain guiding significance for the precision forming process and automatic production of automotive half shaft.

基金项目：

河南省高等学校重点科研项目(24B430021)

作者简介：张培彦（1979-），男，硕士，副教授,E-mail：zpy20230627@163.com

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