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Influence of radial forging process on strain inhomogeneity of hollow gear shaft using finite element method and orthogonal design

借助数值模拟和正交设计探究径向锻工艺参数对空心轴应变不均匀性的影响

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Abstract

Due to the current trend towards lightweight design in automotive industry, hollow stepped gear shafts for automobile and its radial forging process are widely investigated. Utilizing coupled finite element thermo-mechanical model, radial forging process of a hollow stepped gear shaft for automobile was simulated. The optimal combination of three process parameters including initial temperature, rotation rate and radial reduction was also selected using orthogonal design method. To examine the strain inhomogeneity of the forging workpiece, the strain inhomogeneity factor was introduced. The results reveal that the maximum effective strain and the minimum effective strain appeared in the outermost and innermost zones of different cross sections for the hollow stepped gear shaft, respectively. Optimal forging parameters are determined as a combination of initial temperature of 780 °C, rotation rate of 21°/stroke and radial reduction of 3 mm.

摘要

鉴于当前汽车轻量化设计的趋势, 车用空心阶梯齿轮轴及其径向锻造工艺(RFP)得到了广泛研究. 借助热力耦合有限元模型, 模拟了空心阶梯齿轮轴的径向锻造工艺. 此外, 采用正交实验设计方法, 获得了温度、 旋转角度、 径向压下量等工艺参数对成形过程的影响, 并采用应变不均匀性因子评价锻造工件应变的不均程度. 研究表明, 横截面上的最大、 最小应变分别出现在空心阶梯齿轮轴内径和外径边缘. 该径向锻造最优工艺参数组合为温度为 780 °C, 旋转角度为21 °/冲程, 径向压下量为 3 mm.

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Authors and Affiliations

  1. College of Materials Science and Engineering, Chongqing University, Chongqing, 400030, China

    Hong-xu Li  (李洪旭), Kai Wang  (王开), Rong Luo  (罗容), Zi-zong Zhu  (朱子宗) & Shuai Deng  (邓帅)

  2. Chongqing Key Laboratory of Metal Additive Manufacturing (3D Printing), Chongqing, 400030, China

    Hong-xu Li  (李洪旭) & Kai Wang  (王开)

  3. Chongqing Jianshe Industry (Group) Co., Ltd., Chongqing, 400054, China

    Rong Luo  (罗荣), Jing-yi Zhang  (张靖翊) & Fei-song Fang  (方飞松)

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  1. Hong-xu Li  (李洪旭)
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  2. Kai Wang  (王开)
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  3. Rong Luo  (罗容)
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  4. Zi-zong Zhu  (朱子宗)
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  6. Rong Luo  (罗荣)
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Correspondence to Kai Wang  (王开) or Zi-zong Zhu  (朱子宗).

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Foundation item: Projects(51774054, 51974050) supported by the National Natural Science Foundation of China

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Li, Hx., Wang, K., Luo, R. et al. Influence of radial forging process on strain inhomogeneity of hollow gear shaft using finite element method and orthogonal design. J. Cent. South Univ. 27, 1666–1677 (2020). https://doi.org/10.1007/s11771-020-4398-7

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  • DOI: https://doi.org/10.1007/s11771-020-4398-7

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