摘要
胀压成形是制造大尺寸复杂形状汽车桥壳管件的新工艺,成形性好、所需内压低,但成形机理尚不明晰,尚未有明确的内外压确定方法。简介胀压成形工艺,分析了预成形管坯充液压制过程,揭示出横截面小圆角及大圆弧区的成形机理,推导出应力大小与内压、外压的表达式;提出内压、外压的施加准则,给出初始内压的计算公式及压制方式的数学表达式。针对某轴荷10 t桥壳管件的胀压成形过程进行了有限元模拟,结果表明横截面小圆角、大圆弧区的应力状态及其变化趋势同理论分析一致,揭示了小圆角两侧剪切应力的变化规律,得到了最佳内压系数nf、压制系数ks。进行了桥壳管件胀压成形工程试验,实测模具压制力及样件典型横截面的小圆角尺寸、大圆弧区壁厚,相同条件下的有限元模拟与试验结果吻合,最大偏差为6.81%。
Bulging-pressing is a new technology for manufacturing large-size and complex automobile axle housing pipe, which has good formability and low internal pressure. However, the forming mechanism is not clear and there is no definite method to determine the internal and external pressure. The technology is introduced and the process of hydro-pressing of preformed tube blank is analyzed.The forming mechanism of small fillet and large arc area of cross section is revealed, and the expressions of stress, internal pressure and external pressure are derived. The application criteria of internal pressure and external pressure are put forward, and the calculation formula of initial internal pressure and the expression of pressing mode are given. The finite element analysis of the bulging-pressing of a 10 t axle housing pipe was carried out, and the results show that the stress state and changing trend of small fillet and large circular arc are consistent with the theoretical analysis. The variation law of shear stress is revealed, and the optimal internal pressure coefficient nf and pressing coefficient ks are obtained. The engineering tests were carried out, and the pressing force of molds,the small fillet size and the wall thickness of the large arc were measured. The results show that the finite element simulation values under the same conditions are consistent with the experimental results, the maximum deviation is 6.81%.
作者
王晓迪
王连东
金淼
刘恒
徐世旺
WANG Xiaodi;WANG Liandong;JIN Miao;LIU Heng;XU Shiwang(School of Mechanical Engineering,Yanshan University,Qinhuangdao 066004;College of Vehicles and Energy,Yanshan University,Qinhuangdao 066004)
出处
《机械工程学报》
EI
CAS
CSCD
北大核心
2022年第4期62-71,共10页
Journal of Mechanical Engineering
基金
国家自然科学基金(52075474)
河北省重大科技成果转化专项(20282202Z)资助项目。
关键词
汽车桥壳
胀压成形
剪切应力
压制方式
施加准则
automobile axle housing
hydro-pressing
shear stress
pressing method
application criteria
