Finite Element Simulation Of New Process For Pulley Spinning

Spinning easily manufactures the product of whole seamless hollow rotary body. It has many advantages, including good deformation conditions, excellent product performance, precise dimensional tolerances, high material utilization ratio, great product categories and so on. It has been widely application in aviation, shipping, military, civil and other metal precision forming technology departments. This paper combined with the actual production process problems. Air-conditioning clutch pulley and wide flat belt pulley's spinning are regarded as the main research contents. Based on the FEM simulation technology to modification product processes, optimize process parameters and effectively improve the product quality.Air-conditioning clutch pulley is a double-barrel-shaped part with a flange, is an important part of air-conditioning clutches. If using the traditional forging blank by machining and welding to produce, it'll not only cost complex process and more working hours, but also bring low material utilization and high cost. After repeated trials the researchers developed a new type of spinning method:shovel spinning, directly from the flat blank for a double-barrel-shaped. First of all, using DEFORM software established the shovel spinning FEM model and verified simulation results through testing. Then, the value of forming load as the target use orthogonal test to optimize the process parameters. Finally, simulating the results of optimization, the value of forming load decrease and get satisfactory results. Study shows that in ensuring the quality and productivity, larger speed and feed rate, reasonable fillet radius and roller diameter to reduce the value of forming load and to protect the roller.Flat pulley is generally used for high-speed transmission because of stable operation and reliable transmission. In order to prevent belt slippage in start-up and operation, usually need to process rim convexity. In this paper, a wide flat pulley, without processing rim convexity, but stuck with the belt at both ends of the slope to ensure the drive is running. In the process of the pulley's spinning forming, the use of split-type pre-spinning wheel instead of squeeze-type pre-spinning wheel, reducing the forming load and is conducive to forming pulley and extends service life of the spinning wheel. To verify the feasibility of new technology, respectively simulated two different spinning processes, achieved the stress field, the strain filed, the load curve with stroke and so on. These simulation results were compared, further to demonstrate the advantages of new technology. Analysis of the process parameters on the wide flat pulley spinning, provide a reference for the produce debugging. The study shows that using the new technology can reduce the forming load and improve production efficiency.Shovel spinning of air-conditioning clutch pulley and flat belt pulley spinning, research findings of these two kinds of spinning technology have a certain amount of guidance on actual production.