双质量飞轮驱动齿盘旋压增厚成形工艺研究

针对汽车双质量飞轮驱动齿盘外缘为原始板厚的3~5倍的特点,以SIMUFACT软件分析为手段,对双质量飞轮驱动齿盘多道次旋压增厚成形工艺进行研究.基于旋压增厚成形工艺的理论分析,设计出多道次旋压增厚模具并建立了旋压增厚成形有限元模型.以第1道次旋压增厚成形为例,分析了成形过程中应力场分布及板坯的变形情况.同时在板坯表面设置4个测量点分析第1道次旋压增厚成形过程中金属的流动规律,从而总结出第2至5道次的旋压增厚成形规律.以旋轮进给速度、摩擦系数、芯模转速为自变量,进行三因素三水平正交试验,获得最大成形载荷、增厚程度数据.结合灰色理论对双质量飞轮驱动齿盘旋压增厚成形工艺参数进行了优化,在CDC-4S80旋压机上进行了试验,结果表明:在旋压增厚过程中板坯所受径向力最大、切向力次之、轴向力最小;较小的摩擦系数与旋轮进给速度有利于提高零件的成形质量;通过物理试验成功将板坯外缘由3 mm增厚到10.5 mm,验证了该成形方案与灰色系统理论优化的可行性.

Study on spinning thickening forming process of double mass flywheel drive plate

According to the rim of dual mass flywheel (DMFW) drive plate is 3~5 times thicker than the original thin plate, such formation of multi-steps spinning thickening forming process was investigated based on the SIMUFACT software. According to the analysis of spinning thickening deformation, the mould and the finite element model of spinning thickening forming were established. Taking the 1st step spinning thickening forming as an example, the stress field distribution and the deformation of the sheet metal during the forming process were analyzed. Meanwhile, 4 measuring points on the surface of the plate were used to analyze the metal flowing in the 1st step spinning thickening forming process, and such forming rules of the steps ranging from 2 to 5 were summarized. Taking the roller feed speed, friction factor and rotation rate as independent variables, Three factors and three levels orthogonal experiments were carried out to obtain the maximum forming load and thickening rate data. The grey system theory was used to optimize the process parameters of the spinning thickening forming of DMFW drive plate, Such experiments were conducting on the CDC-4S80 spinning machine. The results show that the radial force is the largest, the tangential force is the second, and the axial force is the smallest, in the process of spinning thickening forming, ; The smaller friction and the roller feed rate can improve the quality of forming parts. The rim of the plate was thickened from 3 mm to 10.5 mm by physical test, which verifies the feasibility of the forming process and the grey system theory.