Design And Numerical Simulation Of Plastic Forming Process For Vehicle Tooth Clutch Hub

With the increasingly fierce international competition in the automotive industry and the increasing emphasis on environmental protection,the requirements for lightweight,precise,efficient,low energy consumption,and low cost for the design and manufacture of automotive parts are increasing.In recent years,the application of automatic transmissions in vehicles has become more and more extensive.In the clutch of one of its key parts,the use of a tooth clutch hub can reduce the weight of the automatic transmission,make full use of its internal space,and reduce energy consumption using vehicles.The tooth clutch hub is a stepped deep cylinder type thin-walled part with a large surface area.The tooth profile is uniformly distributed in the circumferential direction,and the thickness of inner and outer tooth wall and the thickness of side tooth wall are uneven.The inner and outer tooth shape fillets are smaller and the outer tooth crest There are also oil holes.Because the clutch hub needs to be used in conjunction with friction plates and other parts,the requirements for forming quality are high,which makes it difficult to forming.At present,it mainly uses casting to form and assist a large number of cutting processes to manufacture clutch hubs,or import foreign equipment and complete sets of plastic forming technology in China,or even directly import parts.In order to improve the competitiveness of related industries,high-quality,low-cost manufacturing of tooth clutch hub parts,it is extremely necessary to study the precise and efficient plastic forming process.The forming of clutch hub tooth is the difficulty and technical key for plastic forming the entire part.Based on the analysis of the structural characteristics of the clutch hub parts,this paper formulates the plastic forming scheme and complete process flow of the clutch hub,and analyzes and calculates the relevant parameters of the main processes;especially for the plastic forming of the hub tooth,stamping extrusion and axial rolling extrusion Designing three types of forming methods and a variety of forming process schemes;In view of the unparalleled superiority of numerical simulation in the study of new plastic forming processes,the numerical simulation and comparison of the forming processes for the above forming schemes are given The influence rules of the relevant parameters and the optimal selection of parameters.Three forming schemes of hub tooth stamping extrusion technology,internal and external tooth synchronous forming,internal and external tooth stepping forming and internal and external tooth progressive forming are designed.Through numerical analysis and comparative analysis of the stress-strain field,tooth filling,die load and springback after the forming process,the optimal plan of progressive extrusion was determined,and the suboptimal plan of step extrusion was discussed,and then the progressive extrusion was discussed.The influence of key parameters such as die angle,squeeze speed and friction on the forming of the concave die on the forming,and reasonable parameters are given.With reference to the global,the axial rolling extrusion of hub tooth proposed in recent years,a new three-point rolling forming scheme was studied and designed;by comparing and analyzing the stress-strain field distribution,hub tooth and fillet formability and forming during forming The load and springback have verified the feasibility of the three-point rolling extrusion scheme,which can not only avoid the problems of the limited number of clutch hub tooth,limited die space,and difficult installation and debugging of the roller and the die,but also reduce It has unique advantages in terms of load,improved metal fluidity,and convenient adjustment of processing parameters.The calculation results show that although the three-point rolling extrusion of the hub tooth is larger than the unloading rebound of the overall rolling extrusion,it fully meets the tolerance requirements of the parts.Aiming at the three-point axial rolling extrusion,the influence of key process parameters such as the diameter of the roller and the moving speed of the punch are further analyzed and optimized.Based on the analysis of the rolling forming process of block-like toothed parts such as gears and splines and the characteristics of clutch hub parts,a three-roll rolling forming process of clutch hub tooth is proposed,and the stress and strain distribution and forming during the forming process are proposed.Finite element numerical simulation calculations were carried out on loads and fillet fills.The results show that the three-roll rolling process can be used to form the clutch hub tooth and has a good forming effect.On this basis,the effects of key parameters such as roll speed and friction on formability were further discussed,and better parameters were determined.