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乘用汽车传动轴中的三脚突缘是一种形状较复杂的零件,在端部面有三个分叉枝和凸台,其成形难度大,对成形工艺要求高。根据三脚突缘锻件的特点,采用一种半封闭挤压代替传统的预锻工艺,利用有限元数值模拟软件DEFORM-3D模拟了半封闭挤压成形和终锻成形过程,获得了相应的载荷—行程曲线、等效应变和等效应力分布规律,并做了相应的模具应力分析。另外,由于锻件所在模具型腔较浅,切边定位困难,为了避免切边时产生错位和变形,将切边、整形工序设计成一套复合模。最后通过小批量试验,验证了三脚突缘成形新工艺的可行性。
The tripod flange in the drive shaft of a passenger car is a kind of complicated part. There are three bifurcated branches and bosses on the end face, which are difficult to form and require high forming technology. According to the characteristics of three-legged flange forging, a semi-closed extrusion was adopted instead of the traditional pre-forging process. The semi-closed extrusion and final forging process were simulated by finite element numerical simulation software DEFORM-3D. Corresponding load- Stroke curve, equivalent strain and equivalent stress distribution law, and made the corresponding mold stress analysis. In addition, due to the shallow mold cavity where the forging, trimming edge positioning difficulties, in order to avoid misalignment and deformation when trimming, the trimming, shaping process designed as a complex model. At last, the feasibility of the new process of forming flange with three feet was verified by the experiment of small batch.