变速箱长柄法兰轴工艺分析及模具关键结构设计

目的 根据长柄法兰轴的结构特点，制定一套产品的成形工艺方案并投入到生产中。方法 法兰轴是双离合器变速器输出端与差速器连接的重要零件，其形状复杂，成形难度较大，根据产品的特点，制定温锻–冷锻联合成形的工艺方案。针对温锻工序中锻件内腔难以充满的问题，利用DEFORM对工艺中的关键步骤进行模拟仿真，并根据模拟结果对模具进行补偿设计，使锻件内腔底部与模具之间的间隙降至0.3 mm以下。考虑到金属的剧烈流动会加重模具的磨损，设计一套模具润滑系统，以提高模具的使用寿命。而锻造过程中模腔内形成密闭空间，压缩的空气会阻碍金属充填型腔，因此，在凹模与凸模上设计出一套模具排气系统，以避免塌角缺陷的产生。结果 实现了长柄法兰轴工件的工业化生产，生产效率可达每分钟12.5只。结论 根据数值模拟的结果对模腔面进行优化，设计了一套模具的润滑结构与排气结构，避免了锻造缺陷的产生，为双离合器变速箱长柄法兰轴产品的温冷锻工艺生产提供了经验依据。

Process Analysis of Long Handle Flange Shaft of Gearbox and Key Structure Design of Die

The work aims to develop a set of product forming process and put into production according to the structural characteristics of long handle flange shaft. Flange shaft is an important part connecting the output end of dual clutch transmission with the differential, which is complex in shape and difficult to form. Based on the characteristics of the product, a process scheme of combined warm-cold forging was developed. In order to improve the filling performance of the forging inner cavity in the warm forging process, the key steps were simulated in DEFORM. The compensation design of the die was carried out according to the simulation results, and the gap between the bottom of the forging inner cavity and the die was reduced to less than 0.3 mm. Considering that the violent flow of metal would aggravate the wear of the mold, a set of mold lubrication system was designed to improve the service life of the mold. In the forging process, a closed space was formed in the die cavity, and the compressed air would hinder the metal filling cavity. Therefore, a set of die exhaust system was designed on the concave die and punch die to avoid the generation of the collapse angle defect. Finally, the industrial production of the long handle flange shaft workpiece was realized, and the production efficiency can reach 12.5 pieces per minute. It is concluded that according to the results of numerical simulation, the mold cavity surface is optimized. A set of mold lubrication structure and exhaust structure are designed to avoid forging defects. It provides an empirical basis supporting the use of combined warm-cold forging process in the production of the long handle flange shaft of the dual clutch gearbox.