Transactions of Materials and Heat Treatment

Title：Precision forming process analysis and numerical simulation of automotive gear shaft parts

Authors： Chen Yingying Zhang Ying Gong Hongying Ji Zhongchao Liao Zehuan Xu Zhimin

Unit： Shanghai University of Engineering Science Shanghai Dongfu & KOAL Cold Forging Manufacturing Co. Ltd.

KeyWords： gear shaft cold extrusion back pressure forming process numerical simulation tooth end filling

ClassificationCode：TG376.3

year,vol(issue):pagenumber：2017,42(12):68-74

Abstract：

Two cold extrusion process schemes of automotive gear shaft part were presented which were the scheme 1 without back pressure device and scheme 2 with back pressure device, and the cold extrusion mold with back pressure device was designed. Then, the finite element models of two process schemes were established, and their forming processes were simulated by software Deform-3D respectively. The simulation results show that when scheme 2 is applied, the maximum values of equivalent stress, equivalent strain, damage and forming load are lower than those of scheme 1, and the forming quality is better. Meanwhile material is saved by 22% for scheme 2 compared with that of scheme 1, and the forming load is only 86% of that of scheme 1. Furthermore, the forming processes of scheme 1 and scheme 2 were verified by experiments respectively. The experimental results show that the gear shaft parts produced by scheme 1 still has the defect of insufficient filling teeth end. However, the teeth is completely filled, and no forming defect is found in gear shafts formed by scheme 2. Finally, scheme 2 is proved to be the better forming process scheme.

Funds：

上海工程技术大学研究生科研创新资助项目(16KY0511)；上海高校青年教师培养资助计划项目(ZZGCD15035)；上海工程技术大学科研启动基金项目(校启2015-06)；上海工程技术大学产学研合作重大项目((17)CL-003)

作者简介：陈莹莹(1991-),女,硕士研究生 E-mail：18800233159@163.com 通讯作者：张莹(1980-)，女，博士，讲师 E-mail：jerrinzhang@163.com

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