CN114310175A - Closed type rear torsion beam manufacturing process based on hydraulic forming process - Google Patents
Closed type rear torsion beam manufacturing process based on hydraulic forming process Download PDFInfo
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- CN114310175A CN114310175A CN202111632920.1A CN202111632920A CN114310175A CN 114310175 A CN114310175 A CN 114310175A CN 202111632920 A CN202111632920 A CN 202111632920A CN 114310175 A CN114310175 A CN 114310175A
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Abstract
The invention discloses a closed type rear torsion beam manufacturing process based on a hydraulic forming process, which comprises the following steps of: s1, establishing a mould profile tool body according to the product structure and size, and then importing the tool body into CAE software for simulation analysis; s2, after the process feasibility analysis in the step S1 is confirmed to be qualified, designing and manufacturing a tool for die assembly production of the rear torsion beam cross beam and the left and right trailing arms; s3, placing the part produced by the tool of S2 into a hydraulic preforming die for prepressing; s4, putting the pre-pressed part into a final forming hydraulic die and performing final punch forming; s5, cutting the redundant parts of the parts obtained by final punch forming; s6, performing heat treatment on the cut parts; and S7, welding the shock absorber support, the spring seat and the parts cut in the S6 respectively to obtain the torsion beam finally. The invention ensures the strength and quality of the trailing arm assembly by reducing the number of welding seams on the trailing arm assembly.
Description
Technical Field
The invention relates to the technical field of automobile rear torsion beams, in particular to a closed rear torsion beam manufacturing process based on a hydraulic forming process.
Background
The two wheels are not directly connected by a hard shaft, but are connected by a torsion beam, and the torsion beam can twist within a certain range. If one wheel meets an uneven road surface, the torsion beam between the wheels still generates certain interference on the other wheel, and in a strict sense, the torsion beam belongs to a semi-independent suspension. Torsion beam suspensions are less comfortable than free-standing suspensions in terms of structure, but are simple and reliable in structure, and have lower maintenance costs than free-standing suspensions, so they are used for rear suspensions of small and compact vehicles.
Because the cost of raw materials is continuously increased, cost reduction and efficiency improvement become key work targets of various automobile manufacturers, and due to the limitation of technical conditions, the middle cross beam structure of the front rear torsion beam shaft assembly is basically an open beam. In the rear torsion beam with the traditional structure, except for basic parts such as a left longitudinal arm, a right longitudinal arm, a rubber sleeve assembly, a torsion beam, a spring seat support and the like, parts such as a torsion bar, a lower reinforcing part, a torsion bar connecting part and the like are added in the middle of the beam for improving the rigidity of a product, the weight of the product is large, the number of welding seams is large, the welding process is complicated, the cost of the product is high, and the risk of product cracking is indirectly increased.
Disclosure of Invention
The invention provides a closed type rear torsion beam manufacturing process based on a hydraulic forming process, which ensures the strength and quality of a trailing arm assembly by reducing the number of welding seams on the trailing arm assembly.
The technical scheme for realizing the purpose is as follows:
the closed rear torsion beam manufacturing process based on the hydraulic forming process comprises the following steps:
s1, establishing a mould profile tool body according to the product structure and size, and then carrying out simulation analysis on the tool body;
s2, after the process feasibility analysis in the step S1 is confirmed to be qualified, designing and manufacturing a tool for die assembly production of the rear torsion beam cross beam and the left and right trailing arms;
s3, placing the part produced by the tool of S2 into a hydraulic preforming die for prepressing;
s4, putting the pre-pressed part into a final forming hydraulic die and performing final punch forming;
s5, cutting the redundant parts of the parts obtained by final punch forming;
s6, carrying out heat treatment on the cut part to eliminate the forming stress of the part;
and S7, respectively welding the shock absorber support, the spring seat, the tire support, the wire harness support and the oil pipe support with the parts cut in the S6 to finally obtain the torsion beam.
And the simulation analysis is to introduce the workpiece body into CAE software for analysis.
The heat treatment is annealing.
The annealing temperature is 800 +/-30 ℃ and the annealing time is 20 minutes.
And carrying out surface treatment on the heat-treated part by pickling or shot blasting to remove oxide scales on the surface of the part.
The shot diameter of the shot blasting is 4mm, and the shot blasting time is 10 minutes
According to the invention, on the basis of the torsion beam with the traditional structure, the cross beam is changed from plate punch forming to hydraulic forming of a pipe through an advanced manufacturing process, and through structural optimization and CAE analysis, the material thickness is reduced, the number of parts and welding lines is reduced, the product weight is reduced, the production and manufacturing cost of the product is reduced, the risk of welding line cracking is reduced, and the competitive advantage of the product is increased. Compared with the traditional stamping part scheme, the hydraulic forming part has obvious advantages. The hydroforming according to the invention has the following advantages:
the strength and the rigidity (more than 5 percent) of the part are improved, and the service life is prolonged;
reducing 5 parts, reducing weight by 4.25KG and reducing weight by about 20%;
the welding seam is reduced by 594mm, the percentage is reduced by 12.3%, and the risk of welding seam cracking is reduced;
the part profile and the welding assembly precision are obviously improved, and the problems of abnormal sound, cracking and the like of a product are reduced.
Detailed Description
The invention relates to a closed type rear torsion beam manufacturing process based on a hydraulic forming process, which comprises the following steps of:
1. establishing a numerical analysis model
S1, according to the part profile, establishing a mould profile tool body by using three-dimensional software UG or CATIA, wherein the mould has two sequences of pre-forming and final forming, and then importing the tool body into CAE software to perform corresponding action setting, tool body profile and CAE analysis process. The beam hydroforming pressure is 200MPa, and the required maximum die clamping pressure is 2640 t. The final maximum thinning rate of the part is 9.5%, the part has no fracture danger points in the hydraulic forming process, the sticking degree of each key section is good, the formed wall thickness is uniform and has no wrinkle, and the process analysis is feasible.
The hydroforming beam digital-analog analysis further comprises the following:
(1) crossbeam length 1124mm, the material is SPFH590, the mouth of pipe size: 66.67mm 101.7mm, tube thickness: 3.5mm and the weight of the part is 7.86 Kg.
(2) Welding the lapping surface, wherein the tolerance of the molded surface is plus or minus 0.5mm, the tolerance of the lapping seam allowance is plus or minus 0.35mm, the tolerance of other free molded surfaces is plus or minus 0.7mm, the tolerance of the seam allowance is plus or minus 0.7mm, the position tolerance of a welding positioning hole is 0, and the size tolerance is 0-0.1 mm.
2. Design of tooling
After the process feasibility analysis in the step S1 is confirmed to be qualified, a hydraulic forming process is formulated through CAE analysis software, if the CAE analysis current process does not meet the forming requirement, the required product parts are obtained through adjusting the product profile and forming procedures for multiple times, and the basic process of the embodiment is as follows: the method comprises the steps of pipe making, preforming, final forming, laser cutting of overlapped lines, heat treatment and shot blasting, wherein the preforming and the final forming are performed by adopting three-dimensional data after analysis, a required product structure is obtained through two forming processes, after the design of a die is completed, through analysis software, in order to reduce tooling cost and improve production efficiency, a torsion beam cross beam and a left longitudinal arm and a right longitudinal arm are subjected to die assembly production, two process positioning holes are respectively punched by oil cylinders in the hydraulic forming process, and the post-process positioning is used.
3. Preforming
And S3, putting the part produced by the tool of S2 into a hydraulic preforming die for prepressing, selecting a proper press, wherein the press is an 800T oil press, putting the welded pipe into the preforming die, determining the direction of a welding seam, and positioning the welding seam of the embodiment at the side edge of the cross beam, so that the stress of the welding seam is minimum, and the cracking problem in the experimental process is avoided. Detecting the straight steel pipe, and after confirming that no defect exists, drawing the straight steel pipe to obtain a blank with the size as follows: a beam: 100mm by 1320mm by 3.5 mm. The pre-forming die is mainly used for pre-pressing the part into a final-forming shape, so that the pipe fitting can be placed into a final-forming cavity, and the final-forming bulging amount is reduced. The positioning reliability and consistency of parts are considered in the debugging process, and the phenomena of die gnawing and material carrying are avoided.
7. Final forming
And S4, placing the pre-pressed part into a final forming hydraulic die and performing final punch forming. After the product is preformed, the molded surface of the part can not meet the tolerance requirement of the drawing, in order to ensure that the molded surface of the part meets the consistency of the drawing and the product, a hydraulic forming process is added after the product is preformed, the molded surface of the part is completely attached to the molded surface of the hydraulic forming die through pressurization of high-pressure liquid to meet the requirement of the drawing, after a finished product is obtained, the part is scanned and detected, the molded surface is at an out-of-tolerance position, the qualified product of the molded surface is finally obtained through continuous optimization and rectification, and the first stage of the final forming hydraulic die ensures that die components, such as a wedge, a driving oil cylinder, a feeding mechanism and the like, can smoothly, stably and have no interference. The second stage is to improve the grinding rate and finish the workpiece output, and the third stage is to improve the precision of the stamping workpiece and eliminate the problems of material gnawing and the surface of other parts.
8. Laser cutting
And S5, cutting the redundant part of the part obtained by final punch forming. The final formed part also needs to be cut to the shape of the final part. Generally, the method adopts the modes of linear cutting, laser cutting, numerical control milling and the like. Because the molded surface of the part is complex, the laser cutting is used in the invention, and the positioning requirement of the part is reliable and the repeatability is high in the cutting process.
9. Heat treatment and oiling
And S6, carrying out heat treatment on the cut part to eliminate the forming stress of the part. The cut parts are generally annealed at 800 + -30 deg.C for about 20 minutes to relieve the forming stress of the parts. The heat treated parts typically require a surface treatment to remove scale from the surface of the part. The treatment method comprises acid washing, shot blasting and the like, and the shot blasting process is adopted in the embodiment, the diameter of the shot is 4mm, and the shot blasting time is 10 minutes. Qualified parts can be formed through the steps.
10. Tailor welding loading vehicle
And S7, respectively welding the shock absorber support, the spring seat, the tire support, the wire harness support and the oil pipe support with the parts cut in the S6 to finally obtain the torsion beam.
In the process of welding the parts together, systematic matching needs to be carried out on each part, such as the matching of the overlap edge lines of the parts, the debugging of the product size, the debugging of the welding line position and the debugging of the welding line penetration, the consistency of positioning references of all levels of parts is confirmed, on the premise that the consistency of a single part is good and the precision is qualified, the clamp is properly adjusted, various problem points are carefully identified, the closed loop is controlled, and the final welding assembly is ensured to meet the size requirement. After all the problems are debugged to be qualified, the final product is adopted to carry out bench test and road test verification, and the required test times and road test mileage are met, and then the passing acceptance is passed.
The samples obtained with the method of the invention were subjected to the following tests of table 1:
roll stiffness analysis
Roll stiffness constraint mode: left bushing center DOF123, right bushing center DOF13, the right wheel center bearing reaction force measured is: 180N, and the wheel track is 1525 mm.
The roll stiffness was: 365 N.m/deg.
Longitudinal working condition: FX 10760. The beam thickness is 3.0mm, and the maximum MISES stress is: 234MPA
By adopting the scheme, after the trial production of the sample is finished, the bench test verification of multiple batches and multiple samples is carried out according to the test specification, the reliability and the stability of the product are tested according to the verification result, and the main problems and the evasion schemes generated in the bench test and the sample production process are as follows.
Finally, it should be noted that: the above embodiments are only preferred embodiments of the present invention to illustrate the technical solutions of the present invention, but not to limit the technical solutions, and not to limit the patent scope of the present invention; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and the modifications or the substitutions do not make the essence of the corresponding technical solutions depart from the scope of the technical solutions of the embodiments of the present invention.
Claims (6)
1. The closed type rear torsion beam manufacturing process based on the hydraulic forming process is characterized by comprising the following steps of:
s1, establishing a mould profile tool body according to the product structure and size, and then carrying out simulation analysis on the tool body;
s2, after the process feasibility analysis in the step S1 is confirmed to be qualified, designing and manufacturing a tool for die assembly production of the rear torsion beam cross beam and the left and right trailing arms;
s3, placing the part produced by the tool of S2 into a hydraulic preforming die for prepressing;
s4, putting the pre-pressed part into a final forming hydraulic die and performing final punch forming;
s5, cutting the redundant parts of the parts obtained by final punch forming;
s6, carrying out heat treatment on the cut part to eliminate the forming stress of the part;
and S7, respectively welding the shock absorber support, the spring seat, the tire support, the wire harness support and the oil pipe support with the parts cut in the S6 to finally obtain the torsion beam.
2. The closed type rear torsion beam manufacturing process based on the hydroforming process according to claim 1, wherein: and the simulation analysis is to introduce the workpiece body into CAE software for analysis.
3. The closed type rear torsion beam manufacturing process based on the hydroforming process according to claim 1, wherein: the heat treatment is annealing.
4. The closed type rear torsion beam manufacturing process based on the hydroforming process according to claim 3, wherein: the annealing temperature is 800 +/-30 ℃ and the annealing time is 20 minutes.
5. The closed type rear torsion beam manufacturing process based on the hydroforming process according to claim 1, wherein the heat-treated part is surface-treated by pickling or shot blasting to remove scale on the surface of the part.
6. The closed type rear torsion beam manufacturing process based on the hydroforming process according to claim 5, wherein: the shot diameter of the shot blasting is 4mm, and the shot blasting time is 10 minutes.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115647203A (en) * | 2022-11-14 | 2023-01-31 | 海宁正轩汽车轻量化零部件有限公司 | Manufacturing process of automobile beam |
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| CN212499770U (en) * | 2020-04-29 | 2021-02-09 | 广州汽车集团股份有限公司 | Automobile and torsion beam thereof |
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Patent Citations (7)
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| KR20130113816A (en) * | 2012-04-06 | 2013-10-16 | 현대하이스코 주식회사 | Aluminium alloy torsion beam axle and manufacturing method thereof |
| CN105216573A (en) * | 2014-06-06 | 2016-01-06 | 上海宝钢高新技术零部件有限公司 | Tubulose torsion beam and manufacturing process |
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| CN109794729A (en) * | 2017-11-16 | 2019-05-24 | 上海汇众汽车制造有限公司 | The production method of 800MPa high intensity torsion beam crossbeam |
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| CN115647203A (en) * | 2022-11-14 | 2023-01-31 | 海宁正轩汽车轻量化零部件有限公司 | Manufacturing process of automobile beam |
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