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中间轴楔横轧成形工艺数值模拟优化及试验
英文标题:Numerical simulation optimization and test on cross wedge rolling process of intermediate shaft
作者:任伟伟 徐春国 曾健 李攀 
单位:北京机电研究所 
关键词:阶梯轴 中间轴 楔横轧 轧制力 切向摆动 Deform 
分类号:TG335
出版年,卷(期):页码:2017,42(1):66-70
摘要:

楔横轧工艺是一种先进的金属成形工艺,广泛应用于成形汽车变速箱的各种阶梯轴。在成形大尺寸非对称的阶梯轴时,轧制力不平衡会导致轧制过程中轧件在水平方向窜动,台阶尺寸不稳定且出现折叠,严重时无法成形;同时,轧件在切线方向摆动量大,从而造成产品弯曲。为了解决轧件台阶尺寸不稳定及弯曲,选取一种典型的非对称阶梯轴,在断面缩减率未超过75%时,采用两次轧制,选用较为合理的成形角和展宽角,同时对料头进行限制,利用有限元模拟软件Deform模拟分析成形过程,并进行试验。结果表明:采用两次轧制能够有效平衡轧制力,保证轧件尺寸稳定;90°直角形状料头比螺旋状料头更能有效限制轧件切向摆动,防止轧件弯曲。

Cross wedge rolling process is an advanced metal forming technology, which is widely used in forming various stepped shafts in automobile gearbox. When a large-sized asymmetric stepped shaft was formed, the imbalance of rolling force could cause workpiece to move in the horizontal direction during the rolling process, to fold with unstable size of the shaft, and even not to be formed. Meanwhile, the workpiece swung strongly in the tangential direction and bent. In order to solve instability of step size and bending, a typical asymmetric stepped shaft was chosen, when the section reduction rate was less that 75%, the two-time rolling process was adopted, and the reasonable forming angle and stretching angle were chosen too. At the same time, the end of rolling workpiece was controlled, and the forming process was analyzed by finite element simulation software Deform. Then, the test was carried out. The results show that the rolling force is effectively balanced by two-time rolling process, and the workpiece size stability can be ensured. Thus, compared with the workpiece with spiral end, the workpiece with 90°end can more effectively limit the tangential oscillation and prevent bending.

基金项目:
福建省科技计划项目(2014H4025)
作者简介:
任伟伟(1983-),男,博士研究生,工程师 E-mail:renweiwei2009@126.com 通讯作者:徐春国(1970-),男,博士,研究员 E-mail:1390082751@163.com
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