Research On Modeling And Simulation Of The Whole Spinning Process Of Complicated Cylindrical Parts With Internal Tooth

With the development of high-end equipment in the aerospace,aviation and automotive fields,as well as the demand for lightweight components,complex cylindrical pats with high load-bearing,high precision and high reliahility have been widely used in key components.Such components are usually complex in shape,the number of tooth shapes is large,and the size is precise,which is difficult-to-form structure.The use of traditional technology fur forming has disadvantages such as low material utilization,low processing efficiency,and poor dimensional accuracy.Spinning forming technology as a locally continuously loaded plate provides a new way for the forming and manufacturing of such components.However,Due to the complex shape of the overall structure,defects such as insufficient filling of the tooth shape and uneven wall thickness are likely to occur during the spinning forming process.Reasonable process parameters play an important role in suppressing forming defects and improving forming quality.Thereforc,studying the spinning forming process of complex cylindrical parts with internal teeth provides important theoretical guidance for imcgrated and precise manufacturing.This paper takes the clutch hub with internally toothed complex cylindrical parts as the research object,and proposes a precise forming process plan for forming high-quality formed parts by the methnd of multi-wheel and multi-pass staggered spinning;based on the finite element simulation software ABAQUS platform A finite element model of the whole process of multi-rotating and multi-pass offset spinning of cylindrical parts with internal teeth was establislicd,and the stability and reliability of the simulation model were verified,On this basis,the spinning of complex cylindrial parts with interial teeth was established.The distribution of equivalent stress and equivalent strain and the law of material flow at different stages of the press forming process were studied respectively,the characteristics of material deformation and alveolar wall thickness distribution were analyzed,the quality evaluation index of the formed part was proposed,and the effect of different process parameters was studied.The influence law of the quality of the internal gear hub forming part is determined,and a set of optimal process parameters are determined and verified by experiments.The main research contents and conclusions are as follows:According to the structural characteristics of the part,determined the multi-rotating wheel multi-pass staggered spinning forming process plan,the structural size of the relevant mold was designed,and the different spinning trajectories were optimized.The finite element model of the spinning process of complex cylindrical parts with internal teeth was established.Based on the material tensile experiment and friction experiment,the material model parameters are determined;using a combination of global mesh and local refinement method for mesh division,the contact type and boundary condition settings are deeply studied,and the model reliability is finally verified It provides a powerful platform support for analyzing material flow laws and deformation characteristics.Based on the pressure model of complex cylindrical parts with internal teeth,the deformation characteristics of the material at each stage of the pressure forming are analyzed,and the flow law of the material during the forming process and the distribution of the tooth groove wall thickness are ascertained:the maximum equivalent stress and strain area It is the contact area between the roller and the blank;the equivalent stress and strain are distributed in layers along the axial direction of the surface of the forming part at different stages,and are evenly distributed along the circumferential direction;the material in the area where the roller contacts first is easier to flow.It is difficult to fill the material at the fillet of the inner tooth tip of the rear contact wheel;the friction between the core mold and the blank hinders the flow of the material,resulting in the asymmetry of the two sides of the tooth surface and the unevenness of the tooth shape.The effects of different process parameters on the forming process and the quality of the formed parts are studied:as the feed ratio increases,the axial stress on the material decreases,and the circumferential and radial stresses first increase,then decrease and then increase.The stress extreme value of the stress concentration area first decreases and then increases,and the tooth groove wall thickness and wall thickness difference of the spinning part increase;with the increase of the core mold rotation speed,the radial stress increases,and the axial stress increases first When it is large,the circumferential stress is reduced,the stress concentration area and the maximum equivalent stress value are reduced,and the tooth groove wall thickness and wall thickness difference of the spinning part are reduced;the rotation speed of the spinning wheel has little effect on the quality of the formed part.The best process parameters within the range of process parameters studied in this paper are:feed ratio f=1.65mm/r;mandrel rotation speed V=5r/s,rollers rotation speed v=8r/s.