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以汽车发电机使用的P6PL118型多楔带轮为研究对象,提出了一种镦粗成形与旋压成形相结合的工艺方案。基于DEFORM平台对铝合金1100多楔带轮成形过程进行有限元模拟,分析了旋轮进给比、旋轮直径、尾顶压下量和轴向间隙对该成形最大旋压力、主轴扭矩与填充难易度的影响规律,获得了优化的工艺参数。并在旋压机上开展多楔带轮旋压成形实验,研究结果表明,工件齿形填充良好,满足尺寸要求,齿顶和齿底处金属流线清晰,沿齿形外廓线分布。工件在旋压时产生冷作硬化,提高了齿面硬度,增强了耐磨性。
Taking the P6PL118 ribbed belt pulley used in automobile generator as the research object, a process scheme combining upsetting and spinning forming was proposed. Based on the DEFORM platform, the finite element simulation of the forming process of the aluminum alloy ribbed wedge 1100 was carried out. The effects of the rotating ratio of the rotating drum, the diameter of the rotating drum, the amount of the tail pressure and the axial clearance on the maximum spinning pressure, The difficulty of the rules of influence, access to the optimized process parameters. The results of the experiments show that the tooth profile of the workpiece fills well and meets the requirement of size. The metal flow lines on the tooth top and bottom of the tooth are clear and distributed along the outline of the profile. When the workpiece is cold-hardened during spinning, the hardness of the tooth surface is increased and abrasion resistance is enhanced.