Research On Stamping Forming Simulation Of Disk Hub For DSG Dual Clutch

DSG dual clutch is one of the most mature ones and most widely applied atpresent. From engineering point of view, DSG dual clutch has characteristic ofreasonable design, complex structure and accurate fit, many parts of which containsthe most advanced design and manufacturing concept. A DSG dual clutch has threedifferent similar disc hubs in both sizes and shapes, which is an important part ofDSG dual clutch. The forming technology of DSG dual clutch is at the forefront ofsheet metal forming technology, the fact that its related technology has beenmonopolized by foreign companies is become an important factor restricting thedevelopment of double clutch in China.In this paper, a kind of innovative stamping forming process of the parts is putforward to break through the foreign technology blockade. The innovation idea ofcombining punching and extruding for the scheme is different from the conceptutilized in the traditional forming for rotary parts with lateral teeth, such as forging,rolling and turning etc.The simulation on DSG dual clutch is studied used three-dimensional modelingsoftware CATIA and forming finite element simulation software Dynaform andDeform3d in order to verify the feasibility and practicability of the formingtechnology based on the innovation concept. The results show that the forming putforward in this paper is feasible and it has obvious advantages of simple mould, highproduction efficiency and suitable for mass production etc. The main research contentis as follows.(1) The innovation idea of combining punching and extruding is put forwardbased on the knowledge of both structure design and sheet metal forming after comparing the advantages and disadvantages of the traditional forming for rotaryparts with lateral teeth.(2) The related theoretical basis of the finite element simulation and sheet metalforming is introduced, which provides a theoretical basis for subsequent researchwork.(3) Sets of forming process are preliminary drawn up according to the basicknowledge of sheet metal forming, elated experience and structure characteristics ofDSG dual clutch disc hub. The advantages and disadvantages as well as the feasibilityof each scheme is demonstrated using the finite element simulation and a set ofcomplete technological process is ultimately identified.(4) The feasibility of each step procedure is gradually demonstrated through thefinite element simulation technology according to the determined technologicalprocess and all parameters affecting the forming results of each step procedure iscontinually optimized, such as s radius, the friction coefficient, blank-holder force andforming speed. In addition, the nature reason of each parameter influencing theforming quality is given based on the simulation results, which provides somereference for similar research in future.(5) Based on the results of process selection and parameter optimization in thefinite element simulation, the simple mold structure figure of extrusion forming fordisk hub side tooth is drawn up and the reasonable design of both punch and diestructure and discharging device in the mould is given in detail. The mouldparameters, such as clearance between punch and die, press pressure, pressure centerand minimum wall thickness of punch and die, are calculated according to thesimulation results and the related calculation.This research laid the foundation for manufacturing and independent research ofDSG dual clutch disk hub.