Research On Upsetting Extrusion Forming Technology Of Heavy Vehicle Axle Tube

In recent years, automobile manufacturing technology developed rapidly, Major auto manufacturers compete fiercely both in the vehicle performance and the production of auto parts, including the application of new materials, the research of new forming technology, all these aspects attract lots of attention. The axle tube, which is the important and necessary security part of the drive axle housing, bears all the weight of the whole vehicle, and having complex alternating stress in the process of the car moving, so that the quality of the half shaft sleeve is directly related to the safety of the passenger’s life and property. The forming technology of the half shaft sleeve is very mature now, but the common use of the forming scheme is to use bar as the raw material, and then carry out the forming process with many steps. This method not only has low material utilization rate, but also needs many steps, all this affected the production efficiency seriously, and increased the manufacturing error and rejection rate. In order to solve the above defects completely, the major manufacturers all develop new forming technology actively to reduce production costs. So Jilin University put forward that using the tube as raw materials for one time upsetting extruding technology.After analyzing the existing forming scheme of half shaft sleeve, put forward one time upsetting extruding technology that to use the tube as the raw material, abandoned the previous cumbersome process completely, improved the efficiency, and reduced the cost obviously. Once having the mass production, the prospects is immeasurable. In this paper, the main research contents about the new forming technology of half shaft sleeve consist of the following parts:(1)According to the related theory of tube forming and the geometrical characteristics of the half shaft sleeve, designed the drawing of the half shaft sleeve, and the rationality of the forging drawing is verified through the finite element simulation and experiment in the paper. According to the principle of equal volume of metal plastic forming and the design of forging drawing, the size of tube blank is calculated in detail. Finally it is determined to perform the upsetting extruding technology which takes the tube blank as raw materials.(2)Using the forming software DEFORM-3D and finite element method to simulate, not only can verify the rationality of the front design of forging drawing, but also proved the feasibility of pipe blank one time extrusion upsetting through a detailed analysis of the forming result. Optimized several important parameters through orthogonal test, and discussed the influence of various parameters on the forming results, and finally find the combination of the process parameters with the minimum forming load to provide a strong theoretical support for the follow-up work.(3)Because the horizontal hydraulic upsetting press forming half shaft sleeve in this paper has no precedent for reference, so the design has brought great difficulties. After the optimization from a variety of programs, finally designed the structure which is divided into upper and lower concave die in this paper, vertical hydraulic cylinder drives the upper concave die move up and down, and the lower concave die finish the opening and closing. The concave die use the insert structure innovatively, the clamping piece and the forming piece divided from each other is beneficial to the replacement of the mould. The level of hydraulic cylinder drives the horizontal punch extrusion upsetting.(4)In view of the existing horizontal hydraulic upsetting forging machine,we has carried on the detailed theoretical analysis,and proved that it can form axle tube.(5)According to the above research, had finished the sample trial in the axle factory, and verified the rationality of the above research contents.(6) The forming process of the research in this paper has been analyzed from the aspects of engineering application value and proved that can achieve high efficiency, economy and environmental protection effect.