新能源汽车全空心电机轴径向锻造数值模拟优化

目的 利用Simufact–Forming计算机模拟软件，开发汽车全空心电机轴径向锻造工艺。方法 分析了不同锤头入模角、坯料转速以及径向下压量对成形等效应变的影响，并基于实验结果建立了正交实验模型，引入了指标隶属度和综合成形质量系数。结果 得到了最佳工艺参数组合如下：径向下压量为1.25mm，锤头入模角为8°，坯料转速为40 r/min，轴向进给量为3 mm。结论 根据最佳工艺参数组合进行了产品生产验证，得到了内外表面均较光滑且无折叠情况发生的电机轴产品，其内部金属流动方向性明显，为实现全空心新能源汽车电机轴的批量化生产提供了经验依据。

Numerical Simulation and Optimization of Radial Forging for the Hollow Motor Shaft of New Energy Vehicles

The work aims to develop the radial forging process of hollow motor shaft for vehicles by Simufact-Forming computer simulation software. Firstly, the effects of different hammer entry angles, blank speed and radial downward pressure on the forming equivalent strain were analyzed. Based on the experimental results, the orthogonal experimental model was established, and the index membership degree and comprehensive forming quality coefficient were introduced. The optimal combination of process parameters was obtained as follows:the radial downward pressure was 1.25 mm, the hammer entry angle was 8°, the blank speed was 40 r/min, and the axial feed was 3 mm. According to the best combination of process parameters, the product production is verified, and the motor shaft with smooth internal and external surfaces and no folding is obtained, of which the internal metal flow direction is obvious, providing an empirical basis for the mass production of all hollow motor shafts of new energy vehicles.