Near Net Forming Process Analysis And Numerical Simulation Of Electromagnetic Clutch Pulley

As a driving part of automobile,the electromagnetic clutch pulley plays an important role in the production of modern automobile industry.Traditional electromagnetic belt wheel production usually adopts forging press processing method,which has the defects of low production efficiency and waste of raw materials.Therefore,it is necessary to research and develop the near net forming process of electromagnetic belt wheel.This paper focuses on the deep drawing and spinning process of electromagnetic belt wheel,develops the processing process and processing parameters,designs the processing die,and carries on the finite element simulation analysis to the whole process,improves the process defects and completes the orthogonal optimization of the process parameters.According to the principle of invariable volume in the process of plastic deformation,the three-dimensional model of electromagnetic pulley is drawn and the initial blank size is calculated.The structure of the parts of the electromagnetic pulley is analyzed,and the processing procedure of drawing before spinning is formulated.According to the shape change of the blank in the process of processing,and referring to the existing mold design experience,the drawing and spinning mold is designed,and the process scheme is determined.Because the sheet metal drawing process is relatively mature,this article focuses on the analysis of the spinning forming process of the electromagnetic pulley.Combined with the spinning die movement in the actual production process,in the DEFORM-3D finite element software,a spinning simulation model of the electromagnetic pulley is established to analyze the metal flow,stress and strain distribution and forming load changes during the spinning deformation process..The results show that the stress and strain distributions are similar,they are concentrated in the contact area between the roller and the blank,and increase with the feed of the roller;the forming load changes more steadily at the initial stage of the feed of the roller,and after the increase in the feed rate,The forming load fluctuates greatly due to the action of the core mold;the initial design of the final wheel structure makes the partial metal flow too fast when the tooth is formed,resulting in folding defects.After the improvement of the tooth-shaped pre-rotating wheel,the blank metal flows Uniformity eliminates process defects and reduces the forming load to a certain extent.In order to improve the wear of the spinning wheel and prolong the service life of the mold,the spinning forming process of the electromagnetic belt wheel was optimized by orthogonal experiments.Taking the mandrel speed,the feed rate of the rotating wheel,and the diameter of the rotating wheel as the influencing factors,the forming load is the test index,the orthogonal test table is designed,and the optimal process parameter combination is obtained by the test analysis.In order to demonstrate the feasibility of the overall near-net forming process of the electromagnetic belt pulley,a brief simulation analysis of the deep drawing process of the spinning blank is carried out.The results show that the forming quality of the spinning blank after the sheet is deep drawn is good and meets the target size requirements.Therefore,the processing technology designed in this paper is suitable for the near-net forming process of electromagnetic pulleys,and the research conclusions have certain guiding effect on the actual production of pulleys.