汽车变速箱轴类多工位冷精锻关键技术研究.pdfVIP

摘 要 我国轿车工业在20 世纪90 代后进入高速发展期，作为轿车传动系的核心部 件，轿车变速箱轴类件的传统生产工艺已无法满足市场要求，高效、高质、节材、 节能的多工位冷精锻工艺应运而生。根据课题组承担的“轿车变速箱轴类件多工位 精锻技术与自动化生产线装备开发及产业化”项目的需要，本文着重就轿车变速箱 轴类件的多工位冷精锻工艺及模具设计进行研究。 运用塑性成形理论和冷挤压工艺 析了轴类件多工位冷缩经、冷镦锻成形工艺 的成形特点和金属流动规律，并在此基础上设计了轿车变速箱空心轴、实心轴零件 的五工位冷精锻工步图。使用主应力法推导的经验公式计算并确定了成形力等工艺 参数。 建立了空心轴和输入轴多工位冷精锻的刚塑性有限元模型，并采用 DEFORM 软件对其成形过程进行了数值模拟，得到了等效应变场、等效应力场、损伤值场以 及变形行程载荷曲线等详细信息与变形规律。为工艺方案、工艺参数的优化及预测 锻件内部是否产生缺陷提供了理论依据。 根据多工位压力机结构和多工位冷精锻成形工艺的特点以及模具与压力机的 配合关系，对轴类件五工位冷精锻模具进行了设计和优化。 针对江苏太平洋精密锻造有限公司承接的德国用户所需的轿车变速箱输入轴、 输出轴零件，对其多工位精锻工艺和模具进行了实验研究。通过实验，一是得到了 大量的实测数据；二是得到了合格的精密锻件。实验结果充 验证了理论研究成果 的正确性，其总的研究成果可为下一步的产业化提供有效地技术支持。 关键词：空心轴类件 多工位 减径挤压 有限元 模具设计 Abstract Since 1990s, the sedan industry of our country developed in a high-speed. To produce the shaft in gear-box in traditional way cannot suit the requirement of market, so a new method with called multistage cold precision forging has been created. Comparing to the conventional shaft shaping, the new method has a lot of advantages such as more efficient, high-quality, material saving and energy saving. Base on the requirements of the proj ect which has been undertaken by our research team, this paper will discuss the process of the multistage cold precision forging and die design. Base on the plastic forming theory and the cold extrusion process, the shaping characteristics and metal flow ruler of the cold ironing and cold upsetting has been analyzed. Then, the multistage process picture sheet of the hollow shaft and solid shaft has been worked out. According to the design size of the shaft, the forming force of every step has been calculated. The rigid-plastic finite element models of the hollow shaft and solid shaft have been established and the multistage cold precision process numerical simulation by adopting the FEM softwa