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针对取力器传动轴的结构特点,设计了多道次的成形工艺方案,对其中的核心工序塑性扩孔和内花键挤压,运用有限元软件Deform-3D进行了模拟分析。根据分析得到的成形过程中金属材料的流动规律和凸模载荷状况,针对内花键挤压时出现的金属刨削式撕下现象,在凸模冲头花键前端增加导向角并对导向角的角度进行多次模拟试验,选取60°导向角。经小批量生产验证,扩孔和内花键均采用200 t液压机,经多次模拟改进的内花键挤压方案切实可行,扩孔内花键挤压处无切削加工现象,无褶皱、裂纹等缺陷,几何尺寸精度达IT8级,可以投入批量生产。
According to the structural characteristics of power take-off drive shaft, a multi-pass forming process was designed. In the core process, the plastic expansion and internal spline extrusion were carried out. The finite element software Deform-3D was used to simulate and analyze the structure. According to the analysis of metal material flow and punch load condition during the forming process, aiming at the phenomenon of metal rip-off during the internal spline extrusion, the guide angle is increased at the front end of the punch of the punch and the guide angle Many simulation experiments, select the 60 ° steering angle. The small-batch production verification, reaming and internal splines are used 200 t hydraulic press, after repeated simulation of the internal spline extrusion program is feasible, reaming within the spline extrusion without cutting phenomenon, no wrinkles, cracks And other defects, geometric size accuracy of IT8 level, can be put into mass production.