Study On Rotary Bending Forming Process Of Torsional Damper Shell Pulley

The current lightweight research of automotive engine accessory drive systems mainly includes structural optimization design and weight reduction design and forming.The torsional damper connected to the front end of the crankshaft is one of the functional pulley assemblies widely used in the front wheel train.Due to the high complexity and high integration of some metal parts in the pulley assembly,the integration and lightweight forming of shell pulley such revolving parts is a difficult point in current manufacturing.To this end,this paper proposes a rotary bending forming process of plate that combines rotary forming and plate volume forming,and a design rule for the roller structure of a "bending thickening and gathering thickening",which is used for forming shell pulley such revolving parts with complex structure.In order to deeply study the deformation mechanism of the sheet metal during the forming process,the process is subdivided into a secondary turning process and a secondary pass forming process,and a two-turn forming finite element is established by Simufact.forming simulation analysis software.During the radial feeding,the outer edge of the slab is subjected to compression thickening and secondary thickening after bending,and the equivalent stress and material flow in the deformation zone are analyzed by the marking point method.Research is of great significance to the production and development of torsion damper housing pulleys with complex structures.The combination of physical experiment and finite element simulation is used to verify the superiority and feasibility of the plate rotary bending forming process.In this paper,combined with the plate rotary bending forming process and the design of the roller structure,the plate rotary bending forming of the torsion damper shell pulley is realized.Combined with the structural characteristics of shell pulley and the design criteria of the first set of roller structure,the metal flow in the deformation zone is effectively controlled by the curved surface structure of the curved wheel,thereby obtaining the preform for forming the multi-V tooth groove.Through the quantitative analysis of the instantaneous section of the part during the forming process,combined with the design principle of roller structure and material flow rate,the radius of arc surface of roller and central angle of circle are determined.Under the target forming process parameters,the finite element simulation and experimental results are basically same,the end ribs are formed full,and the wall thickness of the characteristic area is thickened to the minimum value,which verifies the theory of plate bending forming and the design rule of the rotating wheel structure feasibility.The research results in this paper promote the application of finite element numerical simulation technology in the field of rotary forming,improve the theory of sheet metal forming,and have important guiding significance and application value for rotary forming of concrete shell pulley.