目的 提高异质金属空心层合轴界面结合强度,实现新能源汽车等领域轴类件的高强度、轻量化与低成本制造。方法 提出42CrMo4/45钢空心层合轴板式波纹楔横轧(Flat-corrugated Cross Wedge Rolling)工艺,基于Simufact.forming软件构建数值模拟模型,分析不同层厚比(1.7∶1、1.25∶1和1.08∶1)与轧制温度(1 000、1 100、1 200 ℃)对成形质量的影响。通过对比分析波纹楔横轧与传统横轧的等效塑性应变分布、等效应力分布及模具z轴方向作用力的变化情况,研究波纹楔对层合轴变形行为的影响规律和界面波纹传递机制。结果 波纹模具轧制阶段的最大轧制力约70 kN,主模具轧制阶段最大轧制力约290 kN,较传统模具增加约45%;波纹楔的对称分布与渐进楔入使外轴表面形成规律性螺旋波纹,内外轴界面处形成互补波纹结构;在层厚比1.7∶1条件下,外轴在轧制初期即表现出明显且均匀的塑性变形分布,内外轴变形协调性最佳,波纹界面传递效果良好,有效抑制了轧制过程中的椭圆化趋势;在层厚比1.25∶1工况下,层合轴坯变形集中在中间部位,出现"中间突出"现象;在层厚比1.08∶1条件下,当轧制进程达到中期时,内轴呈现出大片区域的高等效应变值,存在界面分离及压扁风险。在温度影响方面,在1 100 ℃工况下45钢内轴的界面法向应力分布均匀且普遍高于45钢的屈服强度,该温度确保了良好的界面结合状态。结论 板式波纹楔横轧工艺能够在42CrMo4/45钢空心层合轴形成波纹结合界面,提高轴向抗剪和周向抗扭能力;研究结果为解决传统制备工艺中层合轴界面结合强度不足的问题提供了新思路。
Abstract
The work aims to enhance the interfacial bonding strength of dissimilar metal hollow laminated shafts and achieve high-strength, lightweight, and low-cost shaft components for new energy vehicles and other industrial applications. A flat-corrugated cross wedge rolling process for 42CrMo4/45 steel hollow laminated shafts was proposed. Numerical simulation models were constructed using Simufact.forming software to analyze the effects of different layer thickness ratios (1.7∶1, 1.25∶1, and 1.08∶1) and rolling temperature (1 000, 1 100, 1 200 ℃) on forming quality. By comparing equivalent plastic strain distribution, equivalent stress distribution, and z-axis force between corrugated and traditional cross wedge rolling processes, the effect of corrugated wedges on deformation behavior and interfacial corrugation transfer mechanisms were investigated. The maximum rolling force during the corrugated die rolling stage reached approximately 70 kN, while the master die rolling stage peaked at about 290 kN, representing a 45% increase compared with traditional dies. The symmetrically distributed corrugated wedges progressively penetrated the outer shaft surface, forming regular spiral corrugations on the outer shaft surface and complementary corrugated structures at the inner-outer shaft interface. At a 1.7∶1 layer thickness ratio, the outer shaft exhibited distinct and uniform plastic deformation distribution in the early rolling stage, with optimal coordination between inner and outer shafts, effective corrugation interface transfer, and suppression of ovalization during rolling. At a 1.25∶1 ratio, deformation concentrated in the middle section, showing a “middle bulging” phenomenon. At a 1.08∶1 ratio, by the middle stage of the rolling process, the inner shaft displayed large areas of high equivalent strain values, indicating potential risks of interface separation and flattening. Regarding temperature effects, at 1 100 ℃, the interfacial normal stress distribution was uniform and generally exceeded the yield strength of 45 steel, ensuring good interfacial bonding. In conclusion, the flat-corrugated cross wedge rolling process successfully creates corrugated bonding interfaces in 42CrMo4/45 steel hollow laminated shafts, improving axial shear resistance and circumferential torsional ability. The research results provide a new approach to addressing the insufficient interfacial bonding strength problem in traditionally manufactured laminated shafts.
关键词
层合轴 /
板式楔横轧 /
波纹 /
数值模拟 /
界面
Key words
laminated shaft /
flat cross wedge rolling /
corrugation /
numerical simulation /
interface
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基金
国家自然科学基金(52205403); 浙江省自然科学基金(LY24E050002); 宁波市重点研发计划(2023Z011); 宁波市甬江人才工程-青年创新项目(2023A-157-G); 中国-中东欧国家高校联合教育项目(2023320); 宁波大学“力学+”交叉学科拔尖创新青年基金项目(ZX2025000396)