Research On Numerical Simulation Of Rolling Process Of Solid Steel V-belt Pulley

Solid steel V-belt pulleys are key parts of many important belt driving systems such as car's air conditioners, electric generators and water pumps. Casting or forging and machining are the traditional processes. Rolling is a rotary plastic forming method. Compared with traditional processes, it has many advantages, such as high production efficiency and utilization ratio of raw material, reducing cost etc. So it is a new technology with obvious advantages. Due to its special technology and equipments and complex forming mechanism, parameters are not easily controlled, the inner diameters of workpieces would be enlarged. Besides, so far the theoretical research is not sophisticated enough. These problems hamper wide application of this technology.With the rapid development of computer technology and Finite Element Method (FEM), and large commercial FEM softwares arising, a new way to develop and design forming method is open. The 3-D rolling complex deformation problems which could hardly be solved in the past, such as material flowing rules, forming mechanism, internal stress and strain fields, velocity fields could be solved. Based on 3-D rigid-plastic finite element method, and with DEFORM-3D software, the thesis has realized the numerical simulation of the real process of V-belt pulley rolling firstly.In order to study the rolling forming mechanism conveniently, according to the similar principle, this article designed an experimental V-belt pulley model which is smaller and simplified, Numerical simulation and experimental study of the forming process for this model were carried out. Then numerical simulation of rolling process of an automobile air conditioner V-belt pulley was studied. The numerical simulation technological conditions include: single roll and three rolls, whole heating and inductive localized heating. The main researches include:(1) Through analyzing stress and strain fields and velocity fields in the rolling process, obtained the metal flowing rules on the typical plane. This article has analyzed the reason of the workpiece inner diameter expansion; Studied the roll force change regularity in the rolling process; Analyzed the influence of four kinds of different roll diameters to the forming quality; Analyzed and compared two process: three rolls rolling and single roll rolling.(2) Has conducted the physical simulations and experiments study on the lathe by the lead material, obtained the ideal belt pulley, has confirmed the accuracy of the numerical simulation results.(3) Has analyzed whole heating and inductive localized heating two process's the effective strain and stress in different rolling stage; Compared with two process's biggest roll force in the forming process; Compared with two process's temperature field distribution and workpiece shape in the rolling last stage.The result provides important theoretical basis for the rolling process of belt pulleys, designing dies, forecasting the load and the forming flaws. Based on this paper, further study of the rolling process can be carried out. With the experiments, the numerical simulation models and results can be improved. Such research greatly reduces the development cycle, saves the development cost, with great practical and economic value.