Research On Stamping Technology Of Leaf Spring Lifting Lugs For Three-wheeled Vehicles

Three-wheeled vehicle chassis parts,such as leaf spring lugs,axle housings,etc.,are usually cast.Although the casting process has the advantages of being suitable for blanks with complex outer surfaces or inner cavities,and lower production costs.However,the internal structure of the casting is loose,the unit cell is coarse,and there are often shrinkage porosity,micro-pores,etc.,resulting in insufficient mechanical properties of the casting and low impact resistance;and the production process of the casting involves many processes and procedures,which is difficult to be accurate.Quantitative control;especially the casting process has serious energy consumption and serious environmental pollution.Therefore,this article takes the cast leaf spring lifting lug as the research object,and designs a method of stamping and forming to replace the casting process,which effectively reduces heat energy consumption and reduces environmental pollution.Analyze the structure of the three-wheeled automobile casting lug parts,establish the finite element model of the cast leaf spring lug,use the HyperMesh finite element pre-processing software,analyze the working condition setting of the cast lug in the HyperMesh advanced simulation,and obtain the cast leaf spring Displacement and stress distribution of lifting lugs under a variety of complex working conditions(such as no-load and full-load conditions).The topological structure optimization was carried out.According to the optimization results,sheet metal parts were modeled on the leaf spring lugs,sheet metal leaf spring lugs were generated,and the principles and methods of forming sheet metal parts for castings were summarized.The stamping process route of the sheet metal leaf spring lifting lug was designed,the mold structure was determined according to the process route,and the problem of different equipment affecting the production of the enterprise was discussed.The inspection process of leaf spring lug parts was designed.By detecting the vibration and displacement parameters of leaf spring lug parts under different working conditions,characteristic images of cast leaf spring lugs and stamping leaf spring lugs were obtained.The finished lifting lugs were prepared and equipped with a prototype vehicle.Finally,the whole vehicle test verified the effectiveness of the cast leaf spring lifting lugs optimized as sheet metal leaf spring lifting lugs.The optimized sheet metal leaf spring lifting lugs were analyzed for cost,size grade and strength.After optimization,the stamping lug price was reduced by about 44.2%,the dimensional tolerance was increased by one level,and the mechanical properties were improved.The production process reduces heat energy consumption and reduces environmental pollution.Under the background of carbon peak and carbon neutrality,the results of this research not only have guiding significance for the optimization of three-wheeled automobile castings into sheet metal forming parts,but also have reference value for the modification of casting or forging parts of commercial vehicle enterprises.