Study on Rotary Bending Forming Process of Torsional Damper Shell Pulley

扭转减振器壳体带轮旋弯成形工艺研究

School of Materials Science and Engineering, Hefei University of Technology, Hefei 230009, China

Received: 9 October 2018

Abstract

To study the integral forming process of torsion damper shell pulley with characteristic structure is of great significance for producing and developing of the rotational part such as shell pulley. A processing way was proposed by combining plate bending forming and roller structure design, to integral forming torsion damper shell pulley. A model for two-step bending forming was establishedvia finite element method. Under the radial feeding of roller, the outer edge of plate was subjected to compress thickening and secondary thickened after bending, and effective stress and metal flow in the deformation zone were analyzed by using marking point. Combining with the structural characteristics of shell pulley, a design criterion "rotating thickening, gathering thickening" of roller was proposed. The metal flow in deformation zone was effectively controlled through the characteristic structure of roller, thereby the specific region to forming multi-wedge toothwas obtained. The quantitative analysis of the instantaneous part section in the forming process, combining with the design criteria of roller structure and material flow rate, radius and arc angle of roller were determined. With the objective forming parameters, the comparison between the simulation results and the experimental are basically coincided, the ribs were fully formed and the specific regions was thickened to minimum value, which verified the feasibility of sheet-bulk metal rotary bending forming theory and the design criterion of roller structure.

摘要

针对具有特征结构的扭转减振器壳体带轮的整体成形工艺研究，对壳体带轮这类回转体零件的生产与开发具有重要意义。提出一种结合板材旋弯成形工艺和旋轮结构设计，整体成形扭转减振器壳体带轮。通过有限元模拟，建立两道次旋弯成形模型，旋轮沿径向进给过程中，使板坯外缘发生压缩增厚和弯曲聚料后的二次增厚，并采用标记点法分析变形区等效应力和材料流动。结合壳体带轮结构特点，提出一种"旋弯增厚、聚料增厚"旋轮结构设计准则，通过旋轮特征结构有效控制变形区金属流动，由此获得用于成形多楔齿的特定区域。对成形过程中零件瞬时截面的定量分析，结合旋轮结构设计准则和材料流动速率，确定旋轮弧面半径和圆心角。在目标成形工艺参数下，有限元数值模拟和试验结果基本一致，凸筋成形饱满，特征区域增厚到最小厚度值，验证了金属板材旋弯成形理论和旋轮结构设计准则的可行性。