基于Deform-3D的重型汽车新型同步环精密成形过程有限元分析

摘要

重型汽车新型同步环是一种基本对称结构的、带有3个Y型凸台的环形薄壁型零件，主要用于汽车行驶中平稳快速换档。由于新型同步环形状复杂，成形困难，锻造时极易产生填充不满、折叠等情况,因此合理设计锻造工艺与模具结构是一个关键。利用非线形有限元分析软件Deform-3D对重型汽车新型同步环精密成形过程进行仿真，获得成形过程中的应变、应力、材料流动情况，同时对成形过程中的缺陷如折叠、裂纹，进行预测。通过对同步齿环成形过程分析与缺陷预测，可以有效缩短产品开发周期。%The new synchronizing ring of heavy-duty truck is a basic symmetric ring thm wall part with three Y boss structure. It is mainly used in gearshift. It is a key for forging process and mould design because its complex shape which results in insufficient filling, folding and so on. Analyzing of new synchronizing ring of heavy-duty truck precision forming process with Deform-3D, the strain field and the stress field in the forming process can be solved, meanwhile the faults which possibly occur during the forming like folding and crack can be predicted. The cycle life of new product development is reduced greatly by forming process analyzing and flaw prediction of the synchronizer ring.