重卡花键毂镦锻工艺仿真及优化

针对重卡花键毂闭式镦锻工艺存在纵向飞边、毛刺等问题,通过分析锻件成形工艺,提出整体式和可分式两种镶块模具结构,基于可分式凹模的开式镦锻模具结构,制定了分模面位置在花键毂最大轮廓端部前端面和端部中间两种成形方案,并和整体式凹模成形方案作出对比分析。借助DEFORM-3D软件对两种成形方案进行模拟,根据损伤值大小、应力、应变等对比分析了两种方案的优劣性。结果表明,采用可分式凹模可以有效地解决花键毂横向飞边的存储问题,分模面位置在端部中间时能有效解决切边后的"拉毛刺"问题。最终通过花键毂的实际生产验证了可分式凹模结构且中间分模方案的合理性。

Simulation and optimization on upsetting process for heavy vehicle splined hub

For the longitudinal flash, burr and other issues exited during the closed upsetting process for mass production of heavy vehicle splined hub, the structures of embedded die with integral and separable die were put forward respectively by analyzing the upsetting process. Based on open die upsetting of separable die, two forming schemes on the position of the parting surface in the front face and the middle of the maximum contour of splined hub were developed respectively, and the forming scheme was compared with integral die. There-fore, the forging forming process was analyzed by software DEFORM-3D, and superiority-inferiority of two schemes were analyzed by compa-ring the values of damage, stress and strain and so on. The results show that the storage problem of the lateral flash of splined hub is solved effectively by the use of a separable die, and"galling thorn" problem after trimming can be effectively solved by designing parting surface in the middle. Finally, the feasibility of the separable die structure with a parting surface in the middle is verified in the practical production.