Simulation Method For Spinning Forming Of Pulleys With Multi-Wedge For Engine

Spinning method as the latest multi-wedge pulley processing methods, it is gradually replacing the traditional casting, forging and machining cutting multi-wedge pulley way. Ribbed pulley with its light weight, high precision, energy saving, good dynamic balance and other characteristics, widely used in automotive, aerospace, home appliances and other industries.First of all, this paper introduces the theory of multi-wedge pulley about materials’ nolinear constitutive relation, dynamics explicit formulation finite element method(FEM) and quasi-static analysis method in detail. On the basic of the in-depth study of multi-wedge pulley which shaped up by spinning, it built multi-wedge pulley’s valid numerical simulation model and studied multi-wedge pulley named A based on the software of ABAQUS/Explicit. Finally, it reveals the rule of material’s flow and taking up mechanism by means of the simulation process in which study stress and strain distribution, velocity and displacement distribution and spinning pulley’s load distribution for each step.Secondly, combining with author’s practical design experience, it summarized multi-wedge pulley’s design method of workblank and select method of moulding craft. On the one hand, it verified correctness of multi-wedge pulley’s spinning finite element model, on the other hand, it solved the problem of defect which arose in the process of spinning by simulation analysis thus achieving good results by testing on multi-wedge pulley named A, and contrastive analysis with practical moulding. In the process of test on water pump pulley named B, the problem of "boss" material shortage has been solved by changing the spinning process. In addition, for the prevailing problem of folding pattern of spinning multi-wedge belt pulley and the torque measurement limitations of the experimental conditions, it comes up with press separation-torque experiment to estimate the presence of folding pattern parts torque meets the technical requirements.Most importantly, it discussed the effect from plastic wheel whose craft parameters(such as radial feed named f, reduce distance named h, plastic wheel’s height named H) on the shape of drum moulding:"f" and "h" manily affects the shaped symmetry of the "drum" and poor symmetry will cause the sticking step of the teeth area lack of material; Meanwhile, "H" mainly affects the size of the "drum" forming, if "drum" is too small that will cause the thickening step into tooth area not thickening. And verified plastic wheel’s importance to moulding by multi-wedge pulley named C’s improvement test, furthermore, getting obvious results.Aiming at the problem that the final forming spinning wheel teeth easily broken which frequently occurring in practical produce, we conducted the simulation of force analysis, and found out the reason was that the preform wheel forming Angle design is not reasonable and assemble wheel relative position error is too large. On the premise of guarantee assembly relative position errors, through a series of simulation analysis of the reasonable preform rounds of forming Angle which improve the pully lifetime obviously.The test contrastive analysis’ result as what mentioned before shows that multi-wedge pulley’s spinning moulding simulation method established in this paper can be used for multi-wedge pulley’s moulding analysis.