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花键毂内齿径向滚轧变形特征数值研究

Numerical study on deforming characteristics during radial-feed rolling process for inner tooth of splined hub

  • 摘要: 滚轧成形是复杂型面省力高性能成形的有效途径之一,尤其适用于内齿形的成形。然而,受限于内径空间,花键毂内齿形的滚轧在模具布置及运动实现方面面临极大挑战。本文采用数值方法,探讨了重卡花键毂内齿径向滚轧的变形特征。基于内径空间的约束,采用单滚轧模具。该方案径向进给可通过模具主动运动或工件主动运动来实现。在花键毂径向进给滚轧过程中,齿形形成区域内的轴向齿形同步成形,塑性变形区及高应变区主要集中于工件内表层。研究结果表明,花键毂成形以齿底径向材料流动和沿齿侧材料流动为主,轴向材料流动甚微。与轴向进给滚轧的成形结果对比发现,径向滚轧所得花键毂的齿形中部形状几乎相同,但齿形两端区域的形状差别较大。

     

    Abstract: The rolling forming process is a feasible way to form high-performance complex profiles with energy saving, especially for the inner tooth forming. However, the limited space of the inner diameter poses a significant challenge to the arrangement and movement of the rolling die for the inner tooth rolling of splined hub. Thus, the radial-feed rolling process for the inner tooth of splined hub of a heavy-duty truck was studied by numerical methods. The single rolling die was adopted for the radial-feed rolling process due to the constraints of the inner space. The radial feed can be carried out by the rolling die or the workpiece when a single rolling die is adopted. During the rolling process of splined hub, the axial tooth profile is formed at the same time, and the plastic deformation zone and the high strain zone are concentrated in the inner surface. The main metal flows are the radial metal flow near the tooth root of splined hub and the metal flow along the tooth flank, and the axial metal flow is minimal. Compared with the through-feed rolling process, the shape of the splined hub rolled by radial-feed rolling process shows almost no difference in the middle zone but presents more difference at both ends.

     

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