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1、国内图书分类号：U461.91 国际图书分类号：629.113.011 工程硕士学位论文 轿车转向节臂内高压成形研究 硕 士 研 究 生：谢文才 导师： 苑世剑 教授 申 请 学 位： 工程硕士 学 科 、 专 业： 材料工程 所 在 单 位：第一汽车集团公司 答 辩 日 期： 2006 年 09 月 授予学位单位： 哈尔滨工业大学 Classified Index:U461.91 U.D.C: 629.113.011 Dissertation for the Master Degree in Engineering HYDROFORMING OF TURNING ARM OF A CAR C
2、andidate： Xie Wencai Supervisor： Prof. Yuan Shijian Academic Degree Applied for： Master of Engineering Speciality： Material Engineering Affiliation ： The First Automobile Group Co. Date of Defence： September, 2006 Degree-Conferring-Institution： Harbin Institute of Technology 哈尔滨工业大学工程硕士学位论文 摘摘 要要 转向
3、节臂是汽车底盘转向系统中不可缺少的重要零件，承载一定的弯矩 与扭矩。传统的转向节臂成形工艺是利用板料冲压得到上、下盖板，然后再 点焊成整体结构。这种生产方式模具费用较高，材料利用率低，零件整体刚 度和强度均较差。为解决上述问题，本文研究了采用管材制造转向节臂零件 的内高压成形新工艺。 本文首先设计了转向节臂内高压成形件，并利用 Ansys 软件对其进行了 应力分析，符合使用条件要求。 转向节臂内高压成形件的成形难度是最大膨胀量 73.3%，且轴线为曲 线，因此首先制备了最大膨胀量 71%、壁厚满足要求的瓶形预成形毛坯。 可以用于最终内高压成形。 根据零件形状设计了分模面为曲线、两端为圆形导入段
4、和密封段的终成 形模具。通过预成形将瓶形件相关截面变形为花瓣形截面，以便在终成形时 易于实现合模，并易于成形出矩形截面的外凸圆角。 对比分析几组瓶形件预成形后形状与终成形之间的关系发现：要想终成 形顺利进行，预成形件截面尺寸、上下表面及侧面的凹槽尺寸必须匹配合 理。 通过采用终成形模具进行内高压成形实验，获得了合格的实验件。其最 小壁厚为 1.858mm，满足零件的最小壁厚大于 1.7mm 的要求。 内高压成形件重量为 0.55kg，与原有冲压工艺相比，内高压件重量减 轻 24%，表面为封闭曲面，沿传力臂无焊缝和焊接边，外形美观，强度刚 度提高。由于无焊缝，其疲劳强度将大幅度提高，有助于提高汽
5、车整体的安 全性与可靠性。 关键词关键词 液压成形；内高压成形；预成形；转向节臂液压成形；内高压成形；预成形；转向节臂 - I - 哈尔滨工业大学工程硕士学位论文 Abstract Turning arm bears moment and torque, which is a necessary part of the automobile chassis turning system. The traditional process to form the turning arm is that: the top and bottom covering blank is first stam
6、ped, then they are spotting welded to form whole structure. Using the traditional way, not only the die cost is high and utilization ratio of material is low, but also the integer strength and stiffness of the part are bad. In order to solve these problems, an internal high pressure forming process
7、of using tube to manufacture turning arm parts has been researched in the thesis. In the thesis, we have first designed the internal high pressure part of the turning arm. The analysis of the strain of the part has been checked using ANSYS software. The result meet the operating requirements. To sol
8、ve the difficulties that the parts maximum expansion rate is 73.3% and its axial line is curve, we have first manufactured the bottle shaped performed blank with the maximum expansion rate 71%. So the blank can be used in final internal high pressure forming. According to the shape of the part, the
9、final forming die is designed. Its parting surface is a curve; both ends are circled leading segment and sealing segment. By performing, the related section of the bottom shaped blank is changed into petal-like section. Through this way, we can clamp the die and form the outer convex circular corner
10、 of the rectangular section more easily in the final forming. Comparison is made between some groups of preformed blank and final formed part. We have found that in order to accomplish final forming well, the size of the dents in top surface, bottom surface and side surface of the preformed part mus
11、t match reasonably. Using the final forming die to do internal high pressure experiment, we get the qualified experiment part. The minimum thickness of the experiment part is 1.858mm, which is the minimum thickness allowed. The weight of the hydroforming part is only 0.55kg, 24% lighter than the par
12、t formed by traditional stamping process. The surface of the hydroforming part is - II - 哈尔滨工业大学工程硕士学位论文 closed curved face, and there is no weld bead along the power arm, so its appearance is beautiful. The strength and stiffness of the hydroforming part has also been improved. Because there is no
13、weld bead, its fatigue strength will be improved greatly and will be useful to improve the integer safety and reliability of the car. Keywords: hydroforming; internal high pressure; preform; turning arm - III - 哈尔滨工业大学工程硕士学位论文 目录目录 摘 要.I Abstract. II 第 1 章 绪论.1 1.1 课题背景.1 1.2 内高压成形研究进展.1 1.2.1 内高压成形原理及优点.1 1.2.2 内高压成形国外研究进展.3 1.2.3 内高压成形国内研究进展.8 1.3 内高压成形工艺在汽车构件上的应用.10 1.4 本课题目的和意义.13 1.5 本课题研究内容.
