Transactions of Materials and Heat Treatment

Title：Lightweight design and rotary swaging simulation for automobile transmission shaft

Authors： Zhang Qi Tian Tiantai Zhang Yu Han Bin

Unit： Xi′an Jiaotong University

KeyWords： hollow design lightweight automobile transmission shaft rotary swaging diameter reduction variable wall thickness

ClassificationCode：U466；TG316

year,vol(issue):pagenumber：2023,48(5):266-274

Abstract：

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.

Funds：

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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