CN110802374B - Manufacturing method of variable cross-section automobile driving axle housing - Google Patents
Manufacturing method of variable cross-section automobile driving axle housing Download PDFInfo
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- CN110802374B CN110802374B CN201911125362.2A CN201911125362A CN110802374B CN 110802374 B CN110802374 B CN 110802374B CN 201911125362 A CN201911125362 A CN 201911125362A CN 110802374 B CN110802374 B CN 110802374B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
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Abstract
The invention discloses a method for manufacturing a variable-section automobile driving axle housing, which comprises the steps of determining the specification of a pipe blank according to the technical parameters and geometric characteristic dimensions of the driving axle housing to be formed, and then sequentially carrying out bidirectional square pushing, through square pushing, intermediate-frequency heating, two-end rounding, process hole cutting, intermediate-frequency heating, pre-expansion, final expansion and shaping on the pipe blank to finally obtain the driving axle housing to be formed. The method for manufacturing the variable cross-section automobile driving axle housing does not need to weld the triangular plate insert, avoids product defects caused by welding, improves product quality, adopts variable cross-section blank thermal expansion forming, solves the problem of local thinning in the expansion forming process, and is suitable for manufacturing various axle housings such as round, square and axle housings with reinforcing ribs.
Description
Technical Field
The invention relates to the technical field of machining and manufacturing, in particular to a method for manufacturing a variable-section automobile drive axle housing.
Background
The drive axle of the automobile is positioned at the tail end of a transmission system of the automobile and mainly comprises a main speed reducer, a differential mechanism, a half shaft and a drive axle housing, and has the functions of transmitting the engine torque transmitted by a universal transmission device to drive wheels through the main speed reducer, the differential mechanism, the half shaft and the like to reduce the rotating speed so as to increase the torque; changing the transmission direction of the torque through a bevel gear pair of the main reducer; the differential mechanism realizes the differential action of the wheels at two sides so as to ensure that the wheels at the inner side and the outer side turn at different rotating speeds. The general drive axle structure of a general heavy-duty automobile consists of a drive axle housing 1, a main speed reducer 2, a differential 3, half shafts 4 and a hub 5. The drive axle housing 1 is used as a carrier of a drive axle assembly and is an important basic component for mounting and containing a main speed reducer 2, a differential mechanism 3, a half shaft 4, a hub 5 and a brake drum assembly. Besides the drive axle housing and the 4 assembly parts form a drive axle assembly to realize three main functions, the drive axle housing is also connected with the frame through an elastic suspension frame, and supports the mass of the frame and the assemblies thereon together with the front axle. When the automobile runs, the drive axle is required to bear not only the road reaction force and torque transmitted by the driving wheels, but also the driving force, the driving torque, the braking force and the braking torque transmitted by the transmission shaft, and is transmitted to the frame through the suspension. Therefore, the transaxle case should have sufficient strength, rigidity, and fatigue resistance as a key part for ensuring the reliability and driving safety of the normal operation of the vehicle and a long service life. In addition, the structure of the main speed reducer is required to be as simple as possible on the premise of meeting the use requirement, so that the main speed reducer is convenient to disassemble, assemble and adjust, convenient to manufacture and light in weight.
The driving axle housing consists of a central lute-shaped opening housing and hollow pipe bodies with variable cross sections at two sides, the cross sections of all the cross sections are different greatly, and the maximum cross section is positioned in a transition area between a lute-shaped hole and a square cross section. In the existing method for manufacturing the drive axle housing of the heavy-duty automobile by integral thermal expansion, a constant-section tube blank obtained by integral pushing is adopted, the section size of the tube blank is the square section size of a product, so that the volume of a transition region of a lute hole and the square section is insufficient, in order to form the shape of the product, the method can be realized only by thinning the wall thickness of the region, and in the actual production process, the thinnest part is thinned to 7mm from the original 16 mm. In the existing bulging technology, a single-side shaping and straightening method is adopted no matter cold bulging or hot bulging is adopted. When plastic one side, opposite side metal can produce even takes the deformation, causes axle housing body to appear crooked problem, and the product straightness accuracy is super poor promptly, need solve through the alignment process, causes that the process increases, inefficiency and with high costs scheduling problem.
Disclosure of Invention
The invention aims to provide a method for manufacturing a variable cross-section automobile driving axle housing, which aims to solve the problems in the prior art and improve the production efficiency and quality of the variable cross-section automobile driving axle housing.
In order to achieve the purpose, the invention provides the following scheme:
the invention provides a method for manufacturing a variable cross-section automobile driving axle housing, which comprises the following steps:
(1) determining the diameter and the blanking length of the tube blank according to the technical parameters and the geometric characteristic size of the driving axle housing to be formed and the volume equality principle and the bulging ratio, and then blanking;
(2) two-way pushing, namely pushing the two ends of the tube blank into squares by using a two-way pushing machine;
(3) a penetrating type square pushing machine is used for pushing the middle section of the tube blank into a square;
(4) intermediate frequency heating, namely heating square sections at two ends of the tube blank by using a double-end intermediate frequency furnace;
(5) rounding the two ends, and extruding the heated two ends of the tube blank into a circle by using a double-end horizontal extruder;
(6) cutting a process hole, namely cutting a long strip-shaped process hole from the upper part and the lower part of the middle section of the tube blank (the upper part and the lower part of the lute hole) by using a laser or plasma cutting machine;
(7) intermediate frequency heating, namely heating the process hole section cut in the step (6) to 1150-1200 ℃ by using an intermediate frequency furnace, wherein the heating length is determined according to the size of the lute hole;
(8) pre-expanding, namely conveying the heated pipe blank to a die of a hydraulic press for positioning and clamping, inserting a tapered special-shaped male die into a prefabricated hole for continuous gradual hole expanding from top to bottom, so as to obtain a flat elliptical hole in the middle of the pipe blank, wherein the size of the flat elliptical hole needs to ensure that a final-forming inner core die can be placed into the flat elliptical hole;
(9) final expansion, namely placing the preformed workpiece in a final forming composite die, driving two half core dies of a final forming inner core die to radially expand outwards by a conical punch at the center of an upper die when a special hydraulic press slide block moves downwards, and driving an outer die to radially move inwards by an inclined wedge column carried by the upper die when the two core dies expand outwards to a preset stroke so as to ensure that an outer flange part of a middle shell is shaped;
(10) shaping, namely driving a special-shaped core die arranged in the inner cavity of the transition area of the workpiece to horizontally push outwards along the axial direction through a wedge-shaped punch so as to shape the lute hole and the inner cavity of the transition area; meanwhile, the shaping outer die is driven by hydraulic pressure to enable the large circular arc of the transition area at the outer side of the workpiece to meet the requirements, and the lute hole in the middle of the shaped rear axle housing and the contour of the housing meet the requirements.
Preferably, in the step (2), the push square length, the square section size, the transition circular arc size and the like are determined according to the parameters of the transaxle case to be formed, and the pipe diameter of the middle section of the pipe blank is not changed.
Preferably, in step (3), the square cross-sectional thickness dimension is determined according to the thickness of the lute hole of the transaxle case to be formed.
Preferably, in step (4), the heating length is determined by the square round length of the transaxle case to be formed; in the step (5), the diameter and the length of the circular section are in accordance with the requirements of a drawing; in the step (6), the length and the width of the process hole are determined according to the lute hole inner diameter length of the driving axle housing required to be formed.
Preferably, in the step (8), the size of the oblate elliptical hole is determined by an upper male die, and a shaping section is arranged on the upper male die to prevent the elliptical holes on two sides from being different.
Preferably, the final-forming composite die has the functions of radial inner expansion and external limiting and shaping.
Preferably, in step (9), the final-forming composite die further applies axial force to both sides of the tube blank by a hydraulic cylinder to facilitate metal replenishment to the deformation zone.
Compared with the prior art, the manufacturing method of the variable cross-section automobile driving axle housing has the following technical effects:
the manufacturing method of the variable cross-section automobile driving axle housing improves the production efficiency and quality of the variable cross-section automobile driving axle housing. The manufacturing method of the variable cross-section automobile driving axle housing does not need to weld the triangular plate insert, avoids product defects caused by welding, improves the product quality, and improves the material utilization rate by 20 percent compared with a stamping welding process; the production efficiency is improved by 30 percent compared with the punching and welding process, the equipment and tool investment is reduced by 25 percent, and the total production cost is reduced by 25 percent; the influence of the change of the performance of the raw materials is eliminated, and the problems that the residual stress is large when the central shell is expanded in a cold mode, the stress is eliminated by adopting integral heat treatment, local cracking can be generated due to cold expansion, and the rejection rate is high are solved; the variable cross-section blank is subjected to thermal expansion forming, so that the problem of local thinning in the expansion forming process is solved, and the method is suitable for manufacturing various axle housings such as round, square and axle housings with reinforcing ribs; the traditional thermal expansion axle housing manufacturing method is suitable for the bulging of axle housing bodies with small cross sections, and the manufacturing of axle housings with square cross sections and reinforcing ribs cannot be realized.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without creative efforts.
FIG. 1 is a process flow diagram of a method of manufacturing a variable cross-section automotive transaxle case of the present invention;
FIG. 2 is a schematic structural view of a transaxle case;
FIG. 3 is a schematic structural view of a tubular blank in the manufacturing method of the variable cross-section automotive transaxle case of the present invention;
FIG. 4 is a schematic structural view of a tube blank after being pushed in two directions in the manufacturing method of the variable cross-section automotive transaxle case of the present invention;
FIG. 5 is a schematic structural view of a pierced billet after piercing-pushing in the method of manufacturing a variable cross-section automotive transaxle case of the present invention;
FIG. 6 is a schematic structural diagram of a pipe blank with two ends being pressed and rounded in the manufacturing method of the variable cross-section automobile driving axle housing of the invention;
FIG. 7 is a schematic structural view of the blank after the fabrication of the process holes is cut in the method of manufacturing a variable cross-section automotive transaxle case of the present invention;
FIG. 8 is a schematic structural view of the pre-expanded tubular blank in the method of manufacturing a variable cross-section automotive transaxle case of the present invention;
FIG. 9 is a schematic structural view of the blank after final expansion in the manufacturing method of a variable cross-section automotive transaxle case of the present invention;
fig. 10 is a schematic structural view of a drive axle housing obtained after shaping in the method of manufacturing a variable cross-section automotive drive axle housing of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without inventive effort based on the embodiments of the present invention, are within the scope of the present invention.
The invention aims to provide a method for manufacturing a variable cross-section automobile driving axle housing, which aims to solve the problems in the prior art and improve the production efficiency and quality of the variable cross-section automobile driving axle housing.
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in further detail below.
As shown in fig. 1 to 10: the 457 type 10 shown in FIG. 2 is manufactured by adopting the manufacturing method of the variable cross-section automobile driving axle housing of the embodimentTThe heavy vehicle driving axle housing comprises the following steps:
(1) determining specification and blanking size of the used tube blank according to 457 type 10TThe geometric characteristics and the dimensional parameters of the heavy vehicle driving axle housing are determined to be the diameter D after selecting a proper bulging ratio0219mm, wall thickness 16 mm; and determining the blanking length to be 1295 +/-2 mm (as shown in figure 3) by calculation according to the principle of equal plastic deformation volume.
(2) And (4) performing bidirectional square pushing, namely pushing two ends of the round tube material into a square shape by using a 200-ton bidirectional square pushing machine to obtain a square section of 160mm multiplied by 150mm multiplied by 16mm, as shown in figure 4.
(3) Through type square pushing, the middle section of the blank manufactured above is pushed into square by a 200-ton through type square pushing machine, and the thickness dimension of the square section is according to 457 type 10TThe lute hole thickness of the heavy vehicle driving axle housing is determined, the process prepares a variable cross-section tube blank which is in accordance with the axle housing bulging, and local thinning of stored materials is solved for subsequent bulging, as shown in figure 5.
(4) And (3) intermediate frequency heating, namely heating square sections at two ends of the tube blank by using a double-end intermediate frequency furnace.
(5) The two ends of the heated tube blank are extruded into a circle by a 630-ton horizontal extruder, and the diameter and the length of the circle section are required according to the drawing, as shown in figure 6.
(6) And cutting a prefabricated hole in the middle of the preformed tube blank, and taking the center of the lute hole as a reference to cut an axial narrow and long groove prefabricated hole in the middle of the tube blank. The shape of the preformed hole is as simple as possible, but the size of the preformed hole is determined by taking two aspects into consideration. On one hand, the circumference of the prefabricated hole is approximately equal to that of the formed lute hole, so that local cracking or wall thickness reduction during hole expansion can be prevented. On the other hand, the width of the prefabricated hole is as wide as possible on the premise that the width of the flange capable of forming the periphery of the lute hole meets the requirements, so that the radial deformation amount during broaching can be reduced, deformation of different areas during expanding the hole is coordinated, and local thinning of the lute hole can be prevented. After the two factors are comprehensively considered, the size specification of the prefabricated hole is determined as follows: the axial length is 520mm, the width B is 120mm, and the two axial ends are connected by a semicircle with the radius R being 60mm, as shown in figure 7.
(7) Heating the preformed pipe blank with the prefabricated holes to the initial forging temperature by using an intermediate frequency furnace.
(8) Pre-expanding, after placing in a lower die on a special large-stroke hydraulic press for clamping and positioning, in the downward movement of a slide block of the press, continuously and gradually expanding the hole of the special-shaped male die with taper from top to bottom through a prefabricated hole of the tube blank until the stroke is finished to obtain a preforming process part (as shown in fig. 8) with a middle part similar to a flat elliptical hole, wherein the size of the flat elliptical hole needs to ensure that the final-forming inner core die can be placed in the flat elliptical hole, and the major axis and the minor axis of an ellipse in the flat elliptical hole are respectively about: 500mm, 285 mm.
(9) And final expansion, namely placing the preformed working procedure piece into a lower die of a final forming die for positioning, driving two half inner core dies of the lower die to expand outwards by a conical punch head at the center of the upper die when a press sliding block moves downwards, and driving an outer die of the lower die to move inwards in a radial direction by wedge columns at two sides of the upper die when a certain stroke is reached so as to limit the excircle profile of the shell. In addition, axial force F is applied to the two ends of the tube blank through the hydraulic cylinder in the expansion process, metal can be supplemented into a deformation area, and the local wall thickness of an axial area of the lute hole is prevented from being reduced. The process part obtained by final forming and thermal expansion through multiple actions of internal expansion, external limitation and axial force is shown in fig. 9, wherein the diameter of a lute hole is 410mm, and the outer diameter of a shell-shaped flange is 532 +/-2 mm.
(10) Shaping: in order to eliminate the non-roundness of the lute hole and the flange at the outer side of the lute hole of the rear axle housing in the secondary thermal expansion and to enable the radius of the large circular arc in the shape transition area of the axle housing to be about 250mm, a shaping process is required. On one hand, the shaping of the lute hole and the shaping of the inner cavity of the transition area are realized by horizontally and axially pushing outwards the special-shaped core mold inserted into the inner cavity of the workpiece in the previous working procedure; on the other hand, the outer die is shaped by hydraulic drive, so that the large circular arc after the die is attached to the transition region meets the requirement. After shaping, the lute hole formed by bulging and the outline dimensions of the axle housing both meet the design requirements, as shown in fig. 10.
In the bulging process, the deformation zone is objectively thinned from the small section to the large section. The existing bulging method is solved by repair welding of 4 set squares, so that the machining procedures are increased, the manufacturing cost is also increased, and meanwhile, the product quality is difficult to guarantee due to the welding. In this embodiment, starting from the original blank, a variable-cross-section tube blank for axle housing bulging is prepared, and sufficient metal material is stored in the deformation area in advance, so that the reduction of the deformation area after bulging meets the product design requirements. The manufacturing method of the variable cross-section automobile driving axle housing of the embodiment thoroughly cancels the welding process, and can completely meet the requirements of product drawings. The manufacturing method of the variable cross-section automobile driving axle housing has the advantages of short process flow, high material utilization rate, high efficiency and good quality, and is automated.
The manufacturing method of the variable cross-section automobile driving axle housing utilizes the technology of heating the prefabricated hole tube blank with the intermediate frequency furnace, solves the problem of discontinuous magnetic force lines, and improves the heating efficiency. The pre-bulging male die designed by the embodiment is provided with the oval variable cross-section column with a certain taper in the height direction, and the shaping section is designed, so that the problem that the pre-bulging blank is seriously thinned locally due to too fast axial tension of the pre-bulging blank in the pre-shaping process is avoided, the upper and lower shapes of the pre-bulging blank are consistent, and a foundation is laid for uniform deformation in the final forming process.
In the manufacturing method of the variable cross-section automobile drive axle housing, the final forming die adopts a composite bulging technology that an inner core die expands outwards, an outer die limits the outer diameter of the housing and applies axial force, so that the expanded lute hole and the peripheral housing flange thereof can meet the design requirements, metal is driven to supplement a deformation area by applying the axial force, and the local wall thickness of two axial sides of the lute hole is prevented from being thinned.
In the shaping procedure of the manufacturing method of the variable cross-section automobile driving axle housing, the adopted mould shapes the inner shape and the outer shape; the wedge drives the inner special-shaped mold core to shape the inner cavity of the transition area and the lute hole; and the outer contour of the transition area is shaped by a hydraulic driving outer die. The technology of simultaneous shaping on two sides is adopted, so that the requirement on the straightness of the product can be met, and compared with other bulging technologies, the technology cancels a straightening process and shortens the process flow.
The principle and the implementation mode of the present invention are explained by applying specific examples in the present specification, and the above descriptions of the examples are only used to help understanding the method and the core idea of the present invention; meanwhile, for a person skilled in the art, according to the idea of the present invention, the specific embodiments and the application range may be changed. In view of the above, the present disclosure should not be construed as limiting the invention.
Claims (2)
1. A manufacturing method of a variable cross-section automobile driving axle housing is characterized by comprising the following steps:
(1) determining the diameter and the blanking length of the tube blank according to the technical parameters and the geometric characteristic size of the driving axle housing to be formed and the volume equality principle and the bulging ratio, and then blanking;
(2) the two-way squaring is carried out, two ends of the tube blank are squared by using a two-way squaring machine, the length of the squaring, the size of a square section and the size of a transition arc are determined according to parameters of a driving axle housing to be formed, and the tube diameter of the middle section of the tube blank is unchanged;
(3) a penetrating type square pushing machine is used for pushing the middle section of the tube blank into a square; further preparing a variable-section tube blank for axle housing bulging, and solving the problem of local thinning and storing materials for subsequent bulging; the thickness of the square section is determined according to the thickness of a lute hole of the driving axle housing to be formed;
(4) intermediate frequency heating, namely heating square sections at two ends of the tube blank by using a double-end intermediate frequency furnace;
(5) rounding the two ends, and extruding the heated two ends of the tube blank into a circle by using a double-end horizontal extruder;
(6) cutting a process hole, namely cutting a long-strip-shaped process hole in the upper and lower parts of the middle section of the tube blank, namely the upper and lower surfaces of the lute hole, by using a laser or plasma cutting machine;
(7) intermediate frequency heating, namely heating the process hole section cut in the step (6) to 1150-1200 ℃ by using an intermediate frequency furnace, wherein the heating length is determined according to the size of the lute hole;
(8) pre-expanding, namely conveying the heated tube blank into a die of a hydraulic press for positioning and clamping, inserting a tapered special-shaped male die into a prefabricated hole for continuous gradual reaming from top to bottom, so as to obtain a flat elliptical hole in the middle of the tube blank, wherein the size of the flat elliptical hole needs to ensure that a final-forming inner core die can be placed into the flat elliptical hole, the size of the flat elliptical hole depends on an upper male die, and a shaping section is arranged on the upper male die so as to prevent elliptical holes on two sides from being different;
(9) final expansion, namely placing the preformed workpiece in a final forming composite die, driving two half core dies of a final forming inner core die to radially expand outwards by a conical punch at the center of an upper die when a special hydraulic press slide block moves downwards, and driving an outer die to radially move inwards by an inclined wedge column carried by the upper die when the two core dies expand outwards to a preset stroke so as to ensure that an outer flange part of a middle shell is shaped; the final forming composite die has the functions of radial inner expansion and external limiting and shaping; the final forming composite die also applies axial force to two sides of the tube blank through a hydraulic cylinder so as to conveniently supplement metal to a deformation area;
(10) shaping, namely driving a special-shaped core die arranged in the inner cavity of the transition area of the workpiece to horizontally push outwards along the axial direction through a wedge-shaped punch so as to shape the lute hole and the inner cavity of the transition area; meanwhile, the outer die is hydraulically driven to enable the large circular arc of the transition area on the outer side of the workpiece to meet the requirements, and the lute hole in the middle of the rear axle housing and the contour of the housing meet the requirements after shaping.
2. The method of manufacturing a variable cross-section automotive transaxle case of claim 1 wherein: in the step (4), the heating length is determined by the square rounding length of the driving axle housing to be formed; in the step (5), the diameter and the length of the circular section are in accordance with the requirements of a drawing; in the step (6), the length and the width of the process hole are determined according to the lute hole inner diameter length of the driving axle housing required to be formed.
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| CN201911125362.2A CN110802374B (en) | 2019-11-18 | 2019-11-18 | Manufacturing method of variable cross-section automobile driving axle housing |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN111992983A (en) * | 2019-05-27 | 2020-11-27 | 孙振会 | Trailer axle forming automation method |
| CN111992982A (en) * | 2019-05-27 | 2020-11-27 | 孙振会 | Automatic method for forming integral drive axle |
| CN112643301A (en) * | 2020-12-03 | 2021-04-13 | 河南凤宝重工科技有限公司 | Driving axle housing blank and manufacturing method thereof |
| CN112570488B (en) * | 2020-12-21 | 2022-06-10 | 燕山大学 | Spinning-reducing forming method of stepped pipe blank for small and medium-sized bulging forming automobile axle housing |
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| IT1052358B (en) * | 1974-11-23 | 1981-06-20 | Magyar Vagon Es Gepgyar | PROCEDURE FOR MANUFACTURING AXLE BOXES WITH SPINDLES |
| CN102581051A (en) * | 2011-11-16 | 2012-07-18 | 三门峡合鑫机床有限公司 | Cold extrusion forming method for lute hole of axle housing of automobile drive axle and pressing die forming machine tool |
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| CN107999621A (en) * | 2017-11-29 | 2018-05-08 | 闫永东 | One kind is suitable for the molding shaping mould of automobile axle housing |
| CN108160857A (en) * | 2017-11-29 | 2018-06-15 | 闫永东 | A kind of automobile axle housing |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN107966257A (en) * | 2017-11-20 | 2018-04-27 | 滨州学院 | A kind of variable cross-section airofficer girder construction part bending stiffness computational methods |
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| IT1052358B (en) * | 1974-11-23 | 1981-06-20 | Magyar Vagon Es Gepgyar | PROCEDURE FOR MANUFACTURING AXLE BOXES WITH SPINDLES |
| CN102581051A (en) * | 2011-11-16 | 2012-07-18 | 三门峡合鑫机床有限公司 | Cold extrusion forming method for lute hole of axle housing of automobile drive axle and pressing die forming machine tool |
| CN103624482A (en) * | 2012-08-21 | 2014-03-12 | 湖北奥德车桥有限公司 | Method for forming whole axle housing of automobile drive axle |
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| CN108160857A (en) * | 2017-11-29 | 2018-06-15 | 闫永东 | A kind of automobile axle housing |
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