Study On Analysis Of Multi-wedge Belt Pulley Spinning Process And Defects

As an important mechanical transmission part,the multi-wedge belt pulley is widely used in various mechanical equipment.In general,the traditional production of multi-wedge belt pulley involves multiple technology processes,such as casting,forging,machining,stamping bulging and stamping welding,which is gradually replaced by the spinning process due to its waste of materials,low productivity,required balance treatment and other shortcomings.The dissertation demonstrated the study about the spinning process design,spinning defects and process optimization of multi-wedge belt pulley,focusing on the key technology of multi-wedge belt pulley spinning process.The dissertation analyzed structural dimensions of the multi-wedge belt pulley,and calculated structural dimensions of each operation part as per the principle of constant-volume in plastic deformation and characteristics of material deformation to determine the forming process of multi-wedge belt pulley.Then we researched the main spinning process parameters,selecting reasonable lubricant and coolant,and designed and produced spinning die.Spinning defects was found in the stage of thickening formation by the performed physical tests.The defects of the multi-wedge belt pulley were analyzed.Firstly,the dissertation analyzed the formation mechanism of spinning defects theoretically,and then the numerical simulation for the spinning forming process of multi-wedge belt pulley was conducted through establishing the finite element model of multi-wedge belt pulley spinning forming in DEFORM software in accordance with practical production,to analyze the material flow,stress and strain distribution and load in forming process,so as to explore the formation mechanism of spinning defects.The result indicated that in the thickening formation process of multi-wedge belt pulley,the flow velocity of material in end region was lower than that of opening region,which led to material accumulation in end region,forming flash.Spinning gap was caused by lack of materials at the intersection of the side wall and end region,and the maximum radial stress,circumferential stress and axial stress exceeding the tensile strength of materials.Multi-wedge belt pulley spinning process was improved by adding concave preforming spinning roller,and comparative analysis of the material flow,stress and strain distribution and load of the improved process and the original process was performed.The result showed that the preforming spinning roller was helpful to reasonable partition of material,uniform distribution of stress and strain and reduction of the forming load of spinning roller,which eliminated the spinning defects.Based on the above-mentioned study,the orthogonal test was carried out to optimize the tooth formation of spinning process,with the spindle speed,the spinning roller feed speed and the diameter of the spinning roller as the experiment factors,and roller beard load as the objective of the test.The optimal solution of orthogonal test was verified by CDC-S80 E spinning machine,and the multi-wedge belt pulley which met product quality requirements was produced.