汽车启动齿轮超声辅助挤压成型模拟试验研究

Simulation Experimental Study on Ultrasonic Assisted Extrusion Forming of Automotive Starting Gear

  • 摘要: 本文基于DEFORM-3D软件对汽车启动齿轮的成型过程进行了超声辅助挤压研究,以传统挤压(无超声振动辅助)作为对照试验,建立了有限元模型,分析了挤压成型过程中的载荷、应力场、应变场和成型温度的变化规律,对照试验结果表明,超声辅助振动作用下,峰值载荷降低了4.7%,平均载荷降低了7.5%;最大等效应力降低了9.13%,平均等效应力降低了9.8%;降低了工模具的工作应力和载荷,对服役寿命延长有着潜在的意义。等效应变和成型温度分别提高了9.3%和5%,坯料温度提升有利于提高塑性,降低内应力,等效应变提高,表明材料变形更加充分,流动性更好有利于充满模具型腔。超声辅助挤压相对于传统挤压可以有效降低成型应力,增加材料流动性,对提高成型零件的机械性能有着重要意义。

     

    Abstract: This article conducts ultrasonic assisted extrusion research on the forming process of automotive starting gears based on DEFORM-3D software. Using conventional extrusion (without ultrasonic vibration assistance) as a control experiment, a finite element model is established to analyze the changes in load, stress field, strain field, and forming temperature during the extrusion forming process. The control test results showed that under the action of ultrasound assisted vibration, the peak load decreased by 4.7% and the average load decreased by 7.5%; The maximum equivalent stress decreased by 9.13%, and the average equivalent stress decreased by 9.8%; Reducing the working stress and load of the mold has potential significance for extending its service life. The equivalent strain and forming temperature increased by 9.3% and 5% respectively. The increase in billet temperature is beneficial for improving plasticity and reducing internal stress. The increase in equivalent strain indicates that the material deforms more fully and has better fluidity, which is conducive to filling the mold cavity. Ultrasound assisted extrusion, compared to conventional extrusion, can effectively reduce forming stress, increase material fluidity, and is of great significance for improving the mechanical properties of formed parts.
    Key words: Starting gear; ultrasonic extrusion; stress; strain

     

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