Transactions of Materials and Heat Treatment

Title：Simulation analysis of internal high pressure forming on the rear axle shell of a

Authors： Chang Xue Li Jian Zhu Shujian Su Haidi Wu Liang

Unit： Guangxi University of Science and Technology

KeyWords： rear axle shell internal high pressure forming sliding die simulation analysis lightweight

ClassificationCode：TG394

year,vol(issue):pagenumber：2018,43(9):93-102

Abstract：

For the internal high pressure forming technology of rear axle shell of a car, in order to study the forming law and reduce the experimental cost, the internal high pressure forming experiment of the three-way pipe with the same shape characteristics as the rear axle shell was conducted, and the forming process was simulated by the finite element software DYNAFORM. Then, the correctness of the model establishment and simulation analysis were verified by comparing with the experimental results. Furthermore, the forming die was designed according to the forming process of the rear axle shell of a car, and the forming process was simulated by finite element software. Finally, the wall thickness distribution and the forming of the pipe obtained under the static and sliding conditions of the die were compared. The results show that the die sliding can make material into the bulging area and effectively improve the forming quality. Thus, the influences of the different sliding modes of the die on the forming of the pipe were further studied which provided necessary reference for engineering application.

Funds：

广西自然科学基金项目(2016GXNSFAA380211)；柳州市科学研究与技术开发计划课题(2016C050203)；广西科技大学研究生教育创新计划项目（GKYC201702）

作者简介：常雪（1992-），女，硕士研究生 E-mail：Changxuedeyouxiang@163.com 通讯作者：李健（1980-），男，博士，教授 E-mail:lijian0772@126.com

Reference：

［1］Sun X， Liu J， Lu B， et al. Life cycle assessment-based selection of a sustainable lightweight automotive engine hood design
［J］.International Journal of Life Cycle Assessment，2017， 22(9):1373-1383.

［2］Kaluza A，Kleemann S，Frhlich T，et al. Concurrent design & life cycle engineering in auto motive lightweight component development
［J］.Procedia Cirp，2017，66:16-21.

［3］郑晖, 赵曦雅. 汽车轻量化及铝合金在现代汽车生产中的应用
［J］. 锻压技术, 2016, 41(2):1-6.

Zheng H, Zhao X Y. Application of automobile lightweight and aluminum alloy in modern automobile production
［J］. Forging & Stamping Technology, 2016, 41(2):1-6.

［4］李婕.汽车构造
［M］.北京:机械工业出版社，2015.

Li J. Automobile Construction
［M］. Beijing: China Machine Press, 2015.

［5］李伟，韩英淳，史文库.轻型车后桥壳液压成形仿真与实验研究
［J］.汽车技术，2007,(9):55-58.

Li W, Han Y C, Shi W K. Hydraulic simulation and experimental research on rear axle shell of light vehicle
［J］ .Automobile Technology, 2007, (9): 55-58.

［6］李念冲. 重型汽车驱动桥壳焊装夹具设计研究
［D］. 青岛：青岛理工大学，2016.

Li N C. Design and Research on Welding Fixture for Heavy Duty Truck Drive Axle Housing
［D］. Qingdao: Qingdao University of Technology, 2016.

［7］Pavithra E，Zhu K. Hydroforming developments: Insights of other researchers
［J］.Applied Mechanics & Materials，2012，110-116:1748-1752.

［8］王连东，丁明慧，肖超.胀压成形汽车桥壳性能的有限元模拟与试验
［J］.汽车工程，2016，38(1):127-132.

Wang L D, Ding M H, Xiao C. FEM simulation and experiment on the performance of bulging formed axle housing
［J］ .Automotive Engineering, 2016, 38 (1): 127-132.

［9］Wang L D, Cui Y P, Yang D F. Study of bulging-pressing compound-deforming automobile axle housing with a common press
［J］. Applied Mechanics & Materials, 2012, 217-219:1972-1977.

［10］Zhu W，Xu C，Zhang Y，et al. Research on heavy-duty truck axle housing hydroforming
［J］. Lecture Notes in Electrical Engi-neering, 2013，199:133-142.

［11］Hwang Y M， Hsieh S Y，Kuo N J. Study of large-expansion-ratio tube hydroforming with movable dies
［J］. Key Engineering Materials，2017，725:616-622.

［12］Wada M, Iguchi K，Mizumura M，et al. Weight reduction of axle-housing by large expanded hydroforming technologies
［J］. Automatic Vehicle Technology，2013，(67):90-95.

［13］Nikhare C， Narasimhan K. Limit strains comparison during tube and sheet hydroforming and sheet stamping processes by numerical simulation
［J］. Computers Materials & Continua， 2008，7(1):1-8.

［14］薛克敏，孙大智，李萍.汽车驱动桥壳液压胀形数值模拟及试验研究
［J］.塑性工程学报， 2017，24(3):36-42.

Xue K M, Sun D Z, Li P. Numerical simulation and experimental research on hydraulic bulging of automotive drive axle housing
［J］. Journal of Plasticity Engineering, 2017, 24 (3): 36-42.

［15］Wada M，Iguchi K，Mizumura M，et al. Development of large expansion hydroforming technology achieving three-times expanding
［J］. New Day Iron Live Gold Journal，2013, 81:90-98.

［16］Wada M，Mizumura M，Iguchi K，et al. Large-expansion hydroforming technology achieving three-times expanding
［J］. Procedia Engineering，2014，81:2217-2222.

［17］Wada M， Kanada H， Mizumura M， et al. High expansion ratio hydroforming technology for integrated axle housing
［J］. Journal of the JSTP，2014，55(647):1102-1106.

［18］王少辉，李颖，翁依柳，等. 基于棒材拉伸试验确定金属材料真实应力应变关系的研究
［J］. 塑性工程学报，2017，24(4):138-143.

Wang S H, Li Y, Weng Y L, et al. Research on determining the real stress-strain relationship of metallic materials based on bar tensile test
［J］.Journal of Plasticity Engineering, 2017,24 (4): 138-143.

［19］Wang S G，Gao F S，Cheng F L，et al. Study on three-way pipe′s internal high pressure forming simulation
［J］. Key Engineering Materials，2014，589-590:517-522.

［20］苑世剑. 现代液压成形技术
［M］.北京:国防工业出版社，2009.

Yuan S J. Modern Hydroforming Technology
［M］. Beijing: National Defense Industry Press, 2009.

［21］王鸿基，徐迎强，周结魁. 加载路径对变径管内高压成形影响的模拟研究
［J］.精密成形工程，2012, 4(3):47-50.

Wang H J, Xu Y Q, Zhou J K. A simulation study of the influence of loading path on high-pressure forming in reducing tube
［J］. Journal of Netshape Forming Engineering, 2012, 4(3): 47-50.

［22］陈奉军. 管材径压胀形成形规律的研究
［D］. 桂林：桂林电子科技大学，2009.

Chen F J. Research on the Rule of Tube Diameter Bulging Forming
［D］. Guilin: Guilin University of Electronic Science and Technology, 2009.

Service：

【This site has not yet opened Download Service】【Add Favorite】