目的 针对轮毂轴承法兰盘生产过程存在的成形工序多、生产效率低等问题,根据某型号第三代轮毂轴承法兰盘的结构特点,提出一种多向分流成形工艺,以提高生产效率及材料利用率。方法 首先将高温压缩实验得到的轮毂轴承法兰盘所用材料GCr15钢的真应力-真应变曲线导入Deform-3D中,对轮毂轴承法兰盘的多向分流成形过程进行了模拟分析,分析各冲头载荷-时间曲线、合模力、工件的等效应力场分布、等效应变场分布、关键模具应力分布等。然后根据模拟结果设计相应的模具结构并进行工艺试验研究,最后根据工艺流程设计基于总线控制的自动化生产单元,对生产单元布局及生产单元节拍进行研究。结果 试验得到的轮毂轴承法兰盘锻件充填饱满,没有发现折叠和裂纹等锻造缺陷,经过尺寸检测,均符合锻件图要求,与模拟结果一致性较好,且试验得到的各冲头的最大成形力和模拟得到的各冲头最大成形力误差均不超过3.24%,生产单元节拍为24 s。结论 本文提出的轮毂轴承法兰盘多向分流成形工艺是可行的,能有效提升轮毂轴承法兰盘锻件的材料利用率与生产效率,对该类零件的无飞边成形工艺及自动生产单元建设具有一定的指导意义。
Abstract
To solve the problems of many forming processes and low production efficiency in the production of hub bearing flanges, the work aims to propose a multi-directional split forming process according to the structural characteristics of the third generation hub bearing flange, to improve the production efficiency and material utilization. Firstly, the true stress-strain curve of GCr15 steel, which was obtained from high temperature compression experiment, was imported into DEFORM-3D, and the multi-directional split forming process of hub bearing flanges was simulated and analyzed. The punch load time curve, clamping force, equivalent stress field distribution of workpiece, equivalent strain field distribution, and stress distribution of key dies were analyzed. Then, according to the simulation results, the corresponding die structure was designed and the process test was carried out. Finally, according to the process flow, the automatic production unit based on bus control was designed, and the layout and beat of the production unit were studied. The hub bearing flange forgings obtained from the test were fully filled, and no forging defects such as folding and cracks were found. The dimensional test confirmed that they all met the requirements of the forging drawing, and were in good agreement with the simulation results. The maximum forming force error of each punch obtained from the test and the maximum forming force error of each punch obtained from the simulation were not more than 3.24%, and the production unit beat was 24 s. The multi-directional split forming process of hub bearing flange proposed in this work is formable, which effectively improves the material utilization and production efficiency of hub bearing flange forgings, and has certain guiding significance for the non-flash forming process of such parts and the construction of automatic production units.
关键词
轮毂轴承法兰盘 /
多向分流成形 /
数值模拟 /
工艺试验 /
自动化生产单元
Key words
hub bearing flange /
multi-directional split flow forming /
numerical simulation /
process test /
automatic production unit
{{custom_sec.title}}
{{custom_sec.title}}
{{custom_sec.content}}
参考文献
[1] 邓中迪. 轮毂轴承端面花键旋铆辗压成形特征及工艺参数影响研究[D]. 襄阳: 湖北文理学院, 2025.
DENG Z D.Study on Forming Characteristics and Effects of Process Parameters in Rotary Riveting of Hub Bearing Face Splines[D]. Xiangyang: Hubei University of Arts and Sciences, 2025.
[2] QIU M, ZHANG J M, WANG H J, et al.Multi-Objective Optimization Design of Wheel Hub Bearings Based on Kriging-NSGA-II[J]. Journal of Mechanical Science and Technology, 2024, 38(3): 1341-1353.
[3] KIM Y, CHA C Y, JIN S, et al.Development of a Low Friction High Performance Wheel Bearing Seal[J]. SAE Technical Paper Series, 2019, 1: 2019-1-2135.
[4] ZHU L J, HUANG C, LI X H, et al.A Two-Step Marginal-Restraint Mandrel-Free Spinning Method for Accuracy in Forming Large, Special-Shaped Aluminum Alloy Tank Domes[J]. Metals, 2023, 13(7): 1205.
[5] 高淑芝, 陈一丹, 张义民, 等. 第三代轮毂轴承保证轴向游隙的动态选配方法[J]. 机械设计与制造, 2024(11): 247-250.
GAO S Z, CHEN Y D, ZHANG Y M, et al.Dynamic Selective Assembly Method for Assuring Axial Clearance of the Third Generation Hub Bearing[J]. Machinery Design & Manufacture, 2024(11): 247-250.
[6] 杨益, 胡成亮, 曹民业, 等. 轮毂轴承锻件成形工艺分析与改进[J]. 锻造与冲压, 2023(21): 20.
YANG Y, HU C L, CAO M Y, et al.Analysis and Improvement of Forming Process of the Wheel Hub Bearing Forging[J]. Forging & Metalforming, 2023(21): 20.
[7] 代旭, 王建国, 刘东. 基于碳化物调控的GCr15轴承钢强力旋轧工艺参数优化[J]. 西北工业大学学报, 2025, 43(3): 528-535.
DAI X, WANG J G, LIU D.Optimization of Process Parameters of Strong Spinning of GCr15 Bearing Steel Based on Carbide Control[J]. Journal of Northwestern Polytechnical University, 2025, 43(3): 528-535.
[8] WANG Z X, REN L, ZHANG Y T, et al.Realizing Ultra-Fast Spheroidization of GCr15 Bearing Steel by Analyzing the Correlation of Carbide Dissolution Law and Pulsed Electric Current Parameters through Machine Learning[J]. Acta Metallurgica Sinica (English Letters), 2025, 38(7): 1207-1218.
[9] 国家质量监督检验检疫总局, 中国国家标准化管理委员会. 金属材料室温压缩试验方法: GB/T 7314— 2017[S]. 北京: 中国标准出版社, 2017.
General Administration of Quality Supervision, Inspection and Quarantine of the People's Republic of China, Standardization Administration of the People's Republic of China. Metallic Materials—Compression Test Method at Room Temperature: GB/T 7314—2017[S]. Beijing: Standards Press of China, 2017.
[10] LIU L L, ZHAO G Q, WANG G C, et al.Hot Deformation Behavior and Microstructure Evolution Model of 7055 Aluminum Alloy[J]. Journal of Materials Research and Technology, 2023, 27: 3191-3213.
[11] JAIN R, JAIN S, NAGARJUNA C, et al.A Comprehensive Review on Hot Deformation Behavior of High-Entropy Alloys for High Temperature Applications[J]. Metals and Materials International, 2025, 31(8): 2181-2213.
[12] GAO H, ZHANG B, FAN Y, et al.Study on the Hot Deformation Behavior and Microstructure Evolution of As-Forged GH3625 Alloy[J]. Journal of Materials Research and Technology, 2024, 30: 197-209.
[13] XU X D, ZHANG P C, FANG J F, et al.The Hot Deformation Behavior and Processing Map Analysis of a High-Nitrogen Austenitic Stainless Steel[J]. Journal of Materials Research and Technology, 2024, 33: 1359-1365.
[14] DONG X M, XU J, FENG Z X, et al.Exploring Hot Deformation Behavior of the Solutionized Cu-15Ni-8Sn Alloy through Constitutive Equations and Processing Maps[J]. Journal of Materials Research and Technology, 2024, 29: 2142-2153.
[15] CHEN X C, CHEN H S, NIE H H, et al.Research on Hot Deformation Behavior and Microstructure Characterization of the NiTi Alloy Fabricated by Wire Arc Additive Manufacturing[J]. Journal of Materials Research and Technology, 2024, 33: 9180-9194.
[16] 陶涛, 朱国明, 赵海洋, 等. SAE52100轴承钢高温流变行为及本构模型[J]. 塑性工程学报, 2025, 32(5): 179-187.
TAO T, ZHU G M, ZHAO H Y, et al.High-Temperature Rheological Behavior and Constitutive Model of SAE52100 Bearing Steel[J]. Journal of Plasticity Engineering, 2025, 32(5): 179-187.
[17] LIU Y M, ZHANG Z H, ZHAO F, et al.Hot Deformation Behavior of High-Strength Non-Oriented Silicon Steel Using Machine Learning-Modified Constitutive Model[J]. Journal of Materials Research and Technology, 2024, 32: 1971-1983.
[18] GAO S, HE X K, TANG Z X, et al.Hot Deformation Behavior and Hot Working Window of a Solid Solution Strengthened Ni-Cr-Fe-Based Superalloy[J]. Journal of Materials Research and Technology, 2024, 29: 1377-1389.
[19] FU Y H, ZHANG M B, CHEN X, et al.Hot Deformation Behavior and Process Optimization of TC4-DT Alloy Fabricated by Wire and Arc Additive Manufacturing with In-Situ Forging[J]. Journal of Materials Research and Technology, 2024, 30: 5056-5068.
[20] WANG J Y, LONG Y Z, YANG C X, et al.Hot Deformation Behavior and Extrusion Temperature-Dependent Microstructure, Texture and Mechanical Properties of Mg-1Mn Alloy[J]. Journal of Materials Research and Technology, 2024, 30: 1662-1676.
[21] JIANG Y F, JING H C, XU S Y, et al.Hot Deformation Behavior and Processing Map of Al-Zn-Mg-Cu-Zr Alloy[J]. Journal of Materials Engineering and Performance, 2025, 34(8): 6686-6696.
[22] 白德语, 苏岚, 陈睿博, 等. 高Cr-Mo高温轴承钢热变形行为及热加工图研究[J]. 塑性工程学报, 2025, 32(5): 112-121.
BAI D Y, SU L, CHEN R B, et al.Research on Hot Deformation Behavior and Hot Processing Map of High Cr-Mo High-Temperature Bearing Steel[J]. Journal of Plasticity Engineering, 2025, 32(5): 112-121.
[23] 李有克, 刘东旭. 汽车传动系统突缘叉闭式模锻过程有限元模拟及模具磨损分析[J]. 锻压技术, 2025, 50(5): 64-71.
LI Y K, LIU D X.Finite Element Simulation and Die Wear Analysis of Closed Die Forging Process for Automotive Transmission System Flange Fork[J]. Forging & Stamping Technology, 2025, 50(5): 64-71.
[24] 施文鹏, 黎恒逸, 张元东, 等. 基于DEFORM数值模拟的15Cr14Co12Mo5Ni钢齿轮锻造方案优化[J]. 精密成形工程, 2025, 17(4): 78-86.
SHI W P, LI H Y, ZHANG Y D, et al.Optimization of 15Cr14Co12Mo5Ni Steel Gear Forging Scheme Based on DEFORM Numerical Simulation[J]. Journal of Netshape Forming Engineering, 2025, 17(4): 78-86.
[25] 刘华, 刘百宣. 齿形零件的多向数控流动精密成形技术及应用[J]. 锻造与冲压, 2019(17): 36-40.
LIU H, LIU B X.Precision Multi-Directional Flow Digital Control Forming Technology of Gear-Like Parts[J]. Forging & Metalforming, 2019(17): 36-40.
[26] 张南, 刘庆生, 曾琦, 等. 基于热模锻压力机曲轴锻造自动化生产线的时序设计与优化[J]. 锻压技术, 2022, 47(1): 140-145.
ZHANG N, LIU Q S, ZENG Q, et al.Time Sequence Design and Optimization on Automatic Production Line for Crankshaft Forging Based on Hot Die Forging Press[J]. Forging & Stamping Technology, 2022, 47(1): 140-145.
[27] 王宏斌. 轮毂轴承内圈自动化锻造生产线设计及时序规划[D]. 武汉: 华中科技大学, 2020.
WANG H B.Design and Timing Planning of Automatic Forging Production Line for Inner Ring of Hub Bearing[D]. Wuhan: Huazhong University of Science and Technology, 2020.
基金
河南省科技攻关项目（242102220017）
PDF(15168 KB)
渝公网安备 50010702501719号 渝ICP备15012534号-4
