Simulation Analysis Of High Pressure Forming On The Rear Axle Shell Of A Vehicle Based On Sliding Mold

The internal high pressure forming technology is an advanced forming technology for manufacturing hollow lightweight components,which can be used to solve the difficult problems of various types of special-shaped cross-section hollow pipe fittings that are difficult to process using the traditional manufacturing methods in automotive parts.The rear axle housing is one of the most important components of the automobile.Due to its large expansion rate and complicated cross-sectional shape,it is difficult to meet the modern society's requirements for lightweight components.The internal high pressure forming technology has advantages such as simple process,high quality of formed parts,and small weight,which has attracted much attention in the manufacture of automotive bridge shell large deformation components.Taking the internal high pressure forming of a car rear axle housing as the research object,the method of simulation analysis was used to carry out the exploration of the internal high pressure forming law of large deformed parts of axle shells.A method for combining the experimental and simulation analysis of the T-shaped three-way pipe with the same shape features of the axle housing is studied.Set up a three-way pipe high-pressure forming experimental system and design different types of push-heads for forming experiments.According to the experimental conditions,the three-dimensional software SOLIDWORKS was used to establish the mathematical model of the pipe fittings and the mold,and the forming process was simulated by the nonlinear finite element software DYNAFORM.Comparing the experimental results with the simulation results,the error of the two results is controlled within 4%,which verifies the correctness of the establishment of the finite element model and the simulation analysis method.According to the experimental results,the influence of the push-head shape on the forming of high-expansion structures was revealed.Based on this,a sliding forming die was designed according to the requirements of the forming process for the rear axle housing of a vehicle,and the forming process was simulated using finite element software.Comparing the wall thickness distribution and forming condition of the pipe when the mold is at rest and sliding,and studying the influence rule of internal pressure,mold sliding mode,loading path,mold cavity and other major factors on pipe forming.The results of the study show that in the process of high pressure forming in the axle shell,within a certain pressure range,with the increase of the initial yield pressure,the wall thickness difference of the pipe increases,so as to find suitable for the high pressure forming of a rear axle housing of a vehicle.Initial yield pressure.By comparing the effect of the static and sliding of the mold and the sliding mode of different molds on the formation of the axle housing,the sliding method with faster speed in the early stage can obtain a better prototype of the bridge shell.Analyze the influence of straight line and polyline loading path on the forming of the pipe fittings.It can be concluded that the loading path in the early stage of loading is more suitable for the formation of the axle shell.According to the optimization of the slide mold,the results show that the front end of the mold near the bulging area can effectively increase the uniformity of the tube wall thickness and obtain a tube with better forming effect.