CN107639144B - Hydraulic forming method for driving axle housing by adopting high-strength welded pipe and without annealing - Google Patents
Hydraulic forming method for driving axle housing by adopting high-strength welded pipe and without annealing Download PDFInfo
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- 239000007788 liquid Substances 0.000 claims abstract description 16
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- 238000007493 shaping process Methods 0.000 claims abstract description 13
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- 238000007789 sealing Methods 0.000 claims description 53
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- 239000011265 semifinished product Substances 0.000 claims description 4
- 239000002184 metal Substances 0.000 claims description 2
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- 229910000831 Steel Inorganic materials 0.000 description 4
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Abstract
The invention discloses a hydraulic forming method of a drive axle housing by adopting a high-strength welded pipe and needing no annealing, wherein the welded pipe blank is subjected to twice end push-pull diameter reduction, twice middle hydraulic bulging and once liquid filling pressing forming to prepare the axle housing; the first hydraulic bulging uses a sliding bulging die with a back pressure punch, the bulging amount can reach 1.8 times of tube expansion rate, the thinning rate is not more than 10%, and the middle part of the formed tube blank is an axisymmetric cylinder; the second hydraulic bulging adopts a sliding bulging die with a fixed die, the middle part of the formed tube blank is a non-axisymmetric special-shaped piece, and the thinning rate is not more than 10%; thirdly, filling liquid, pressing and shaping to enable the preformed tube blank to be a front-flat rear-spherical axle housing tube fitting; and cutting off the additional front cover to obtain the axle housing product. The invention has the advantages of light weight, high strength and high material utilization rate of the axle housing hydraulic forming process, has the characteristics of simplified forming process, high production efficiency and the like, and can achieve the purpose of replacing the traditional axle housing stamping and welding process.
Description
Technical Field
The invention belongs to the field of automobile part manufacturing, and relates to a hydraulic forming method of a driving axle housing part.
Background
In recent years, in the automotive field, hydroforming has a tendency to spread out over a range of applications as one of means for weight reduction. Because the thickness of the axle housing can be distributed in a changing way by hydroforming, the rigidity of the hydroformed axle housing is higher than that of the stamping welding axle housing under the condition of equal weight, and the fatigue life is long.
Although forming technology related to hydroforming of an automobile drive axle housing has been presented, such as the integral forming method of a weld-free axle housing of a light and medium truck of CN 103084460B, a composite bulging process method for forming an axle housing by utilizing diameter reduction and sliding type hydraulic bulging is described. The axle housing manufactured by the forming method has the advantages of high material utilization rate, high fatigue life and the like, but has the defects of more manufacturing procedures, high cost, poor cleanliness of the inner cavity of the axle housing and low production efficiency due to the fact that annealing is required to be arranged between bulging procedures. The method adopts the hot-rolled seamless steel tube with lower wall thickness precision for forming, the wall thickness distribution of the hot-rolled seamless steel tube is uneven, the thin part of the tube blank with the wall thickness is easy to burst in the hydraulic forming process, and the yield of products is reduced. The method cannot form a welded pipe with high wall thickness precision, and in the first bulging process, the periphery of a welded seam of the welded pipe is expanded to cause forming failure.
The prior literature also discloses a sliding type hydraulic forming method with a back pressure punch, which can use an STKM11A welded pipe to form a small-sized automobile axle housing without annealing. In the disclosure, both the first and second pre-bulging require back pressure shaping, the third time inner high pressure shaping with the bulging from inside to outside. The method has the following defects:
(1) The pipe expansion rate can reach more than 1.8 times after the first back pressure forming, but the thinning rate of the pipe blank is close to 20%, so that a low-strength pipe with higher elongation rate is needed. This limits the application of this process to drive axles with high load-carrying capacity requirements: the axle housing of the drive axle of the medium and light vehicle is usually manufactured by using high-strength steel with the grade of 350MPa, and the elongation rate of the high-strength steel is generally not more than 25 percent.
(2) The second back pressure forming and the third internal high pressure forming require a large change in the product profile, and have a bottleneck problem of requiring a high internal pressure forming.
Disclosure of Invention
The technical problems to be solved by the invention are as follows: provided is a method for hydroforming a transaxle axle housing which can use a high-strength welded pipe, does not require annealing, has a low forming pressure, and does not greatly change the external shape of the product.
One of the technical schemes of the invention is as follows:
a high-strength welded pipe and a driving axle housing hydraulic forming method without annealing are adopted, and an axle housing is manufactured by pushing and reducing a welded pipe blank at the end part twice, hydraulic bulging at the middle part twice and hydraulic forming at the time;
the first hydraulic bulging uses a sliding bulging die with a back pressure punch, the bulging amount can reach 1.8 times of tube expansion rate, the thinning rate is not more than 10%, and the middle part of the formed tube blank is an axisymmetric cylinder;
the second hydraulic bulging adopts a sliding bulging die with a fixed die, the middle part of the formed tube blank is a non-axisymmetric special-shaped piece, and the thinning rate is not more than 10%;
thirdly, filling liquid, pressing and shaping to enable the preformed tube blank to be a front-flat rear-spherical axle housing tube fitting;
and cutting off the additional plane front cover to obtain the axle housing product.
Further, according to the cross-sectional dimension of the axle housing of the drive axle, i.e. the perimeter L of the middle part of the axle housing 4 Perimeter L of axle housing straight arm 1 Perimeter L of round tubes at two ends of axle housing 2 The process steps of determining the forming method are as follows:
(1) Selecting an outer diameter d 0 Is a welded pipe of (1);
(2) The two ends of the tube blank are pushed and pulled for the first time to shrink the diameter: clamping the middle part of the tube blank on a three-way hydraulic press, synchronously reducing the two sides of the tube blank, and reducing the outer diameter of the diameter reducing part from d 0 Reduced to d 1 ，L 1 ＝2πd 1 The reduction ratio is L 1 /L 0 ；
(3) The two ends of the tube blank are pushed and pulled for the second time for reducing: clamping the middle part of the tube blank on a three-way hydraulic press, synchronously reducing the two sides of the tube blank, and reducing the outer diameter of the diameter reducing part from d 1 Reduced to d 2 ，L 2 ＝2πd 2 The reduction ratio is L 2 /L 1 ；
(4) Sealing ports are processed at two ends of the tube blank;
(5) First hydraulic bulging: the three-way hydraulic press uses a sliding bulging die with a back pressure punch to fill liquid into the tube blank and synchronously push the tube blank from two sides, so that the middle part of the tube blank is bulged, and the outer diameter of the middle section of the tube blank is increased to d 3 ，L 3 ＝2πd 3 Obtaining an axisymmetric cylindrical part with an expansion ratio of L 3 /L 0 =1.7-1.8 times, wall thickness reduction rate not exceeding 10%;
(6) The second hydraulic bulging: the three-way hydraulic press uses a sliding bulging die with a fixed die to fill liquid into the tube blank and synchronously push the tube blank from two sides, so that the middle part of the tube blank is bulged, and the perimeter of the middle section of the tube blank is increased to L 4 Obtaining a non-axisymmetric special-shaped piece; the bulging ratio is L 4 /L 3 1.25-1.3 times, the wall thickness reduction rate is not more than 10%, and the welded pipe weld joint is placed at the horizontal position of the front plane of the axle housing;
(7) Liquid filling press forming: the method comprises the steps of using a pressing die on a four-way hydraulic press, pressing a preformed tube blank from the upper direction, the lower direction, the front direction and the rear direction to obtain a front-flat rear-spherical axle housing semi-finished product, wherein the appearance of the product is consistent with that of a traditional stamping welding axle housing, and the product can be exchanged;
(8) And cutting off the additional plane front cover to obtain the axle housing product.
The second technical scheme of the invention is as follows:
a hydraulic shaping system for axle housing of drive axle with high-strength welded pipe and without annealing is composed of two hydraulic shaping steps, the first hydraulic shaping with slide-type hydraulic shaping mould with back pressure punch, the second hydraulic shaping with slide-type hydraulic shaping mould,
the sliding type hydraulic forming die with the back pressure punch consists of 6 groups of rectangular back pressure punches, back pressure punch cylinders, fixed dies and sliding dies which are uniformly and symmetrically distributed in the radial direction;
a rectangular guide structure is arranged on the fixed mould to provide the guide and limit of the rectangular back pressure punch; providing a constant backpressure punch pressure F by a backpressure punch cylinder;
a rectangular groove is formed in the sliding die adjacent to the rectangular back pressure punch, and the rectangular back pressure punch is in clearance fit with the adjacent sliding die so as to solve the motion interference generated in the forming process of the rectangular back pressure punch and the adjacent sliding die;
the contact surface of the back pressure punch and the tube blank adopts a concave cylindrical surface, and the radius of the cylindrical surface is the radius of the inner cavity of the fixed die.
Preferably, the first hydraulic bulging adopts a sliding hydraulic forming die with a back pressure punch, which comprises a pair of sliding dies and a pair of slotting sliding dies which are symmetrically arranged from outside to inside, an upper die holder, an upper fixed die, a lower fixed die and a lower die holder, wherein the sliding dies are connected with the slotting sliding dies, the outer end of an inner cavity of the slotting sliding die is a tube blank sleeve joint end, and the sliding dies are provided with hydraulic channels communicated with the interior of a tube blank; the slotting sliding die is in sliding connection with a cavity formed by the upper die base and the lower die base through a guide post and guide sleeve structure; the upper fixed mould and the lower fixed mould are arranged at the axial middle position of the cavity, the upper fixed mould and the lower fixed mould are provided with a plurality of groups of rectangular guide grooves and limiting steps which are uniformly and symmetrically distributed in radial direction, a plurality of groups of rectangular back pressure punches slide in the radial direction in the rectangular guide grooves and are limited by the limiting steps, the rectangular back pressure punches are connected with a hydraulic system, and the inner end of an inner cavity of the slotting sliding mould and a preformed deformation cavity of a tube blank formed by a plurality of groups of rectangular back pressure punches.
Preferably, the inner cavity of the sliding die is provided with a sealing sliding block and a sealing pressing block, the sealing pressing block is fixed at a connecting position between the sliding die and the slotting sliding die, the sealing sliding block is axially and slidably connected with the inner cavity of the sliding die, the inner cavity of the sealing pressing block and the inner cavity of the slotting sliding die form a tube blank sleeve joint, and a hydraulic tube hole of the sliding die is communicated with the inside of the tube blank through a middle hole of the sealing sliding block.
Preferably, one end of the sealing slide block is axially connected with the inner cavity wall of the sliding die through a spring assembly, and the other end of the sealing slide block is adjacent to the port of the sealing press block and is provided with a sealing cover structure of a tube orifice of the tube blank.
Preferably, the slotted sliding die is provided with a guide sleeve, and the guide post is arranged on the upper fixed die and the lower fixed die.
Preferably, a plurality of groups of rectangular abdication guide grooves which are uniformly and symmetrically distributed in the radial direction are arranged on the slotting sliding die, and the positions and the directions of the rectangular abdication guide grooves are consistent with those of the rectangular guide grooves.
Preferably, the contact surface of the rectangular back pressure punch and the tube blank is a concave cylindrical cambered surface, the radius of the cylindrical cambered surface is the inner cavity radius of the upper fixed die and the lower fixed die, and the concave cylindrical cambered surface of the rectangular back pressure punch forms a tube blank cylindrical cavity; the rectangular back pressure punch is respectively connected with a back pressure punch cylinder which is fixed on the upper die holder and the lower die holder.
Preferably, the second hydraulic bulging adopts a sliding hydraulic forming die which comprises a pair of second sliding dies, a pair of transition sliding dies, a pair of middle sliding dies, a second upper die holder, a second upper fixed die, a second lower fixed die and a second lower die holder which are symmetrically arranged from outside to inside, wherein the second sliding dies are fixedly connected with the transition sliding dies, and the transition sliding dies and the middle sliding dies are in sliding connection with a cavity formed by the second upper die holder and the second lower fixed die through a second guide post and a second guide sleeve structure; the second upper fixed mould and the second lower fixed mould are arranged at the middle position of the axial direction of the cavity; the outer end of the inner cavity of the transition sliding die is a sleeve joint end of the preformed tube blank, the inner end of the inner cavity of the transition sliding die, the inner cavity of the middle sliding die and a die cavity formed by the second upper fixed die and the second lower fixed die form a preformed deformation cavity of the preformed tube blank, and the second sliding die is provided with a hydraulic channel communicated with the inside of the preformed tube blank.
Preferably, the inner cavity of the second sliding die is provided with a second sealing sliding block and a second sealing pressing block, the second sealing pressing block is fixed at a connecting position between the second sliding die and the transition sliding die, the second sealing sliding block is axially and slidably connected with the inner cavity of the second sliding die, the inner cavity of the second sealing pressing block and the outer end of the inner cavity of the transition sliding die jointly form a sleeve joint of the preformed tube blank, and the hydraulic tube hole of the second sliding die is communicated with the inside of the preformed tube blank through a middle hole of the second sealing sliding block.
Preferably, one end of the second sealing slide block is axially connected with the inner cavity wall of the second sliding die through a second spring assembly, and the other end of the second sealing slide block is adjacent to the port of the second sealing pressing block and is provided with a sealing cover structure for the pipe orifice of the preformed pipe blank.
Preferably, the transition sliding die is provided with a guide hole, the middle sliding die is provided with a second guide sleeve, and the second guide post is symmetrically arranged on the second upper fixed die and the second lower fixed die.
Preferably, the cavity of the intermediate sliding die and the cavity formed by the second upper fixed die and the second lower fixed die form a spheroid-like preform cavity of the preform.
The beneficial effects of the invention are as follows:
1. the manufactured axle housing has reasonable wall thickness distribution, and has higher strength and rigidity than the stamping welding axle housing under the same weight.
2. The appearance of the product is consistent with that of the traditional stamping welding axle housing, and the product can be interchanged.
3. The sliding die with the back pressure punch is adopted for hydraulic bulging, the single bulging amount can reach more than 1.8 times, the wall thickness reduction amount is not more than 10%, and stress relief annealing is not needed after bulging. The stress eliminating annealing procedure is adopted, so that the production efficiency of the axle housing can be improved, and the cleanliness of the inner cavity of the axle housing can be improved. Meanwhile, the sliding die with the back pressure punch is hydraulically expanded, the pressure of the back pressure punch and the expansion internal pressure required in the forming process are smaller, and the tonnage of forming equipment is reduced.
4. The diameter reduction process can be minimized.
5. High strength welded pipe forming may be used.
6. The welded pipe is formed by hydraulic forming, so that the dimensional accuracy of the wall thickness of the pipe blank is improved, and the problem of yield caused by poor wall thickness accuracy of the pipe blank is solved.
In a word, the invention has continued the advantage that the hydraulic forming process of axle housing is light in weight, high in strength, material utilization rate are high, also have made the hydraulic forming process of axle housing simplify, the production efficiency is obviously improved, the hydraulic forming manufacturing cost is obviously reduced advantage, thus can reach the purpose that the hydraulic forming process for the axle housing of the drive axle replaces the traditional stamping welding process.
Drawings
Fig. 1 is a schematic product diagram of a light truck axle housing of example 3.5 tons of the present invention.
Fig. 2 is a schematic side view of a product of a light truck axle housing of example 3.5 tons of the present invention.
Fig. 3 is a schematic view of an initial welded pipe blank according to an embodiment of the present invention.
FIG. 4 is a schematic A-A cross-sectional view of an initial welded pipe blank according to an embodiment of the present invention.
Fig. 5 is a schematic view of a tube blank after the first diameter reduction according to the embodiment of the present invention.
FIG. 6 is a schematic view of a B-B section of a tube blank after a first reduction in diameter according to an embodiment of the present invention.
Fig. 7 is a schematic view of a tube blank after the second reduction in the embodiment of the invention.
FIG. 8 is a schematic C-C section of a tube blank after a second reduction in accordance with an embodiment of the invention.
Fig. 9 is a schematic view of a tube blank after a first hydro-bulging in accordance with an embodiment of the invention.
Fig. 10 is a schematic D-D cross-sectional view of a tube blank after the first hydro-bulging in accordance with the embodiment of the invention.
Fig. 11 is a schematic view of a tube blank after a second hydraulic bulging in accordance with an embodiment of the present invention.
FIG. 12 is a schematic E-E cross-sectional view of a tube blank after a second hydraulic bulging in accordance with an embodiment of the present invention.
Fig. 13 is a schematic view of a tube blank after press forming according to the embodiment of the present invention.
FIG. 14 is a schematic F-F cross-sectional view of a tube blank after press forming according to the embodiment of the invention.
Fig. 15 is a schematic diagram of a die for the first hydro-bulging of an embodiment of the present invention.
Fig. 16 is a schematic cross-sectional view of a die G-G for the first hydro-bulging in accordance with an embodiment of the invention.
Fig. 17 is a schematic diagram of the loading curve of the first hydro-bulge in the embodiment of the present invention.
Fig. 18 is a schematic diagram of a die for a second hydro-bulging in accordance with an embodiment of the present invention.
Fig. 19 is a schematic diagram of the loading curve of the second hydro-bulging in the embodiment of the present invention.
In fig. 15, the die for the first hydro-bulging includes a sliding die 11, a spring assembly 12, a seal ring 13, a seal slider 14, a seal block 15, a connecting bolt 16, a slotted sliding die 17, a rectangular back pressure punch 18, an upper die holder 19, a back pressure punch cylinder 110, an upper fixed die 111, a welded pipe 112, a guide post 113, a guide sleeve 114, a lower fixed die 115, and a lower die holder 116;
in fig. 18, the second hydro-bulging die comprises a second sliding die 21, a second spring assembly 22, a second sealing ring 23, a second sealing slide 24, a second sealing press block 25, a second connecting bolt 26, a transition sliding die 27, a second guide post 28, an intermediate sliding die 29, a second guide sleeve 210, a second upper fixing die 211, a preformed blank 212, a second upper die holder 213, a second lower die holder 214, and a second lower fixing die 215.
Detailed Description
The present invention is described in further detail below by way of specific examples using a high strength welded tube and a drive axle housing hydroforming process without annealing.
Fig. 1-2 are schematic views of a 3.5 ton light truck axle housing according to an embodiment of the present invention, wherein the main appearance parameters include: the wall thickness is 6mm, the height of the middle section of the bridge bag is 340mm, the height of the rear cover is SR163.2, the square section sizes of the two sides of the bridge bag are ≡L1×L196×96mm, the outer diameter of the round section of the two ends of the bridge shell is phi 96mm, and the transition fillets of the bridge bag are R16 and R20. The welded pipe weld 001 is placed at the front plane in fig. 2.
Fig. 15 and 16 are schematic structural views of a first hydro-bulging die according to an embodiment of the present invention. The die body consists of a sliding die 11, a spring assembly 12, a sealing ring 13, a sealing sliding block 14, a sealing pressing block 15, a connecting bolt 16, a slotted sliding die 17, a rectangular back pressure punch 18, an upper die holder 19, a back pressure punch cylinder 110, an upper fixed die 111, a welded tube 112, a guide post 113, a guide sleeve 114, a lower fixed die 115 and a lower die holder 116. The slide die 11 is connected to the slotted slide die 17, and is guided by a guide post 112 and a guide sleeve 113 to slide together in a cavity formed by the upper die holder 19 and the lower die holder 115. The guide post 112 is mounted on the upper and lower fixed dies 111 and 115. 6 groups of rectangular guide grooves 117 and limit steps 118,6 are processed on the upper fixed die 111 and the lower fixed die 115, and the rectangular back pressure punches 18 slide in the rectangular guide grooves 117, and touch the limit steps 118 on the fixed die when forming is finished, so that the back pressure punches stop sliding. The contact surface of the rectangular back pressure punch and the tube blank is a concave cylindrical surface, and the radius of the cylindrical surface is equal to the radius of the inner cavity of the fixed die. The 6 sets of back pressure punch cylinders 110 are respectively connected with the 6 sets of rectangular back pressure punches 18 and fixed on the upper die holder 19 and the lower die holder 116.
Fig. 18 is a schematic structural view of a second hydraulic bulging die according to an embodiment of the present invention. The die body consists of a second sliding die 21, a second spring assembly 22, a second sealing ring 23, a second sealing sliding block 24, a second sealing pressing block 25, a second connecting bolt 26, a transition sliding die 27, a second guide post 28, an intermediate sliding die 29, a second guide sleeve 210, a second upper fixed die 211, a preformed tube blank 212, a second upper die holder 213, a second lower die holder 214 and a second lower fixed die 215. The second sliding die 21, the transition sliding die 27 and the intermediate sliding die 29 are connected, and guide is provided by the second guide post 28 and the second guide sleeve 210, and slide in a cavity formed by the second upper die holder 213 and the second lower die holder 214 together. The second guide post 28 is mounted on the second upper stent 211 and the second lower stent 215.
The hydraulic forming method of the 3.5-ton light truck axle housing comprises the following steps:
(1) The outer diameter d is selected 0 QSTE340TM welded pipe with 134mm and 5.5mm wall thickness, welded pipe parent metal elongation no less than 25%, weld elongation no less than 17%, as shown in fig. 3 and 4.
(2) The two ends of the tube blank are pushed and pulled for the first time to shrink the diameter: clamping the middle part of the tube blank on a three-way hydraulic press, synchronously reducing the two sides of the tube blank, and reducing the outer diameter of the diameter reducing part from d 0 =Φ134mm reduced to d 1 Diameter reduction ratio of L 1 /L 0 =0.85, as shown in fig. 5, 6.
(3) The second push-pull diameter reduction is carried out on the two sides of the tube blank: clamping the middle part of the tube blank on a three-way hydraulic press, synchronously reducing the two sides of the tube blank, and reducing the outer diameter of the diameter reducing part from d 1 =Φ114mm reduced to d 2 =Φ96mm, reduction ratio of L 2 /L 1 =0.84, as shown in fig. 7, 8.
(4) Sealing ports are processed at two ends of the tube blank.
(5) The middle part of the tube blank is subjected to hydraulic bulging for the first time: the first hydraulic bulging die, as shown in fig. 15 and 16, is characterized in that an upper die holder 19 is mounted on an upper vertical slide of a three-way hydraulic press, and a lower die holder 116 is mounted on a workbench. The left and right sliding dies 11 are respectively arranged on the left and right sliding blocks of the hydraulic press; the left and right sliding blocks of the hydraulic press drive the left and right sliding dies to slide respectively, and the vertical sliding blocks of the hydraulic press drive the upper die holder 19 to move up and down.
First, the tube blank is put into a die according to the diagram of fig. 16, and a vertical slide block of a hydraulic press drives an upper die holder 19 to move downwards and to be clamped. The left and right sliding blocks of the hydraulic press respectively drive the sealing sliding block 14, the sealing pressing block 15 and the left and right sliding dies 11 to move together to seal the two ends of the pipe blank. When the gap between the slotted sliding die 17 and the upper fixed die 111 is 180mm, the left and right sliding blocks of the hydraulic machine stop moving. The rectangular back pressure ram 18 clamps the tube blank by the back pressure ram cylinder 110. In fig. 16, 6 sets of rectangular back pressure punches 18 are guided by rectangular grooves in the upper and lower fixed dies 111, 115 by the back pressure punch cylinder to apply back pressure F to the outer surface of the tube blank.
The hydraulic system charges the inside of the pipe blank with liquid and pressurizes P according to the loading curve shown in FIG. 17, and simultaneously the back pressure punch cylinder applies radial back pressure counterforce F to the outer surface of the pipe blank through the rectangular back pressure punch 18. The left and right sliding dies 17 of the hydraulic press synchronously advance from two sides until die closing, so that the middle part of the tube blank is expanded, and the outer diameter of the middle section of the tube blank is increased to d as shown in fig. 9 and 10 3 =Φ240mm, bulging ratio L 3 /L 0 =1.79. The hydraulic system is loaded according to the loading curve shown in fig. 17 as follows:
(6) The second hydraulic bulging of the middle part of the tube blank: the second hydraulic bulging die is shown in fig. 18, a second upper die holder 213 is mounted on the upper vertical slide of the three-way hydraulic press, and a second lower die holder 214 is mounted on the table. The left and right second sliding dies 21 are respectively arranged on the left and right sliding blocks of the hydraulic press; the left and right sliding blocks of the hydraulic press drive the left and right sliding dies to slide respectively, and the vertical sliding blocks of the hydraulic press drive the second upper die holder 213 to move up and down.
First, the tube blank is placed in a mold as shown in fig. 18, and a hydraulic press vertical slide block drives a second upper mold seat 213 to move downwards and mold the tube blank. The left and right sliding blocks of the hydraulic press respectively drive the second sealing sliding block 24, the second sealing pressing block 25 and the left and right second sliding dies 21 to move together so as to seal the two ends of the pipe blank. When the space between the slide die 29 and the second upper fixing die 211 is 25mm, the left and right sliders of the hydraulic machine stop moving.
The hydraulic system charges the interior of the pipe blank with fluid and pressurizes the interior of the pipe blank according to the loading curve shown in fig. 19. The left slide block and the right slide block of the hydraulic press synchronously advance from two sides until the die is closed, so that the middle part of the tube blank is swelled, and the perimeter of the middle section of the tube blank is increased to L 4 About 966mm, an expansion ratio of L 4 /L 3 =1.27, resulting in the non-axisymmetric profile shown in fig. 11, 12.
The hydraulic system is loaded according to the loading curve shown in fig. 19 as follows:
(7) Liquid filling press forming: the preform was pressed from the top-bottom, front-back and four-direction directions with a pressing die in a four-way hydraulic press with the internal pressure of the preform kept constant at 20MPa, and after the completion of the pressing, a shaping pressure was kept at 60MPa to obtain a front-flat rear-spherical axle housing semifinished product, as shown in fig. 13, 14.
(8) And cutting off the additional plane front cover to obtain the axle housing product.
The above-described embodiments are merely illustrative of the principles of the present invention and their applications and are not intended to limit the invention. It should be noted that, without departing from the inventive concept, several variations and modifications can be made to the number of diameter reductions, the sequence of diameter reductions and bulging, the way of guiding the back pressure punch, etc., which are all within the scope of the present invention.
Claims (8)
1. A hydraulic forming method for a drive axle housing by adopting a high-strength welded pipe and needing no annealing is characterized in that the welded pipe blank is subjected to twice end push-pull diameter reduction, twice middle hydraulic bulging and once liquid filling pressing forming to prepare the axle housing;
the first hydraulic bulging uses a sliding bulging die with a back pressure punch, the bulging amount can reach 1.8 times of tube expansion rate, the thinning rate is not more than 10%, and the middle part of the formed tube blank is an axisymmetric cylinder;
the second hydraulic bulging adopts a sliding bulging die with a fixed die, the middle part of the formed tube blank is a non-axisymmetric special-shaped piece, and the thinning rate is not more than 10%;
thirdly, filling liquid, pressing and shaping to enable the preformed tube blank to be a front-flat rear-spherical axle housing tube fitting;
cutting off the additional plane front cover to obtain an axle housing product;
according to the cross-sectional dimension of the axle housing of the drive axle, i.e. the circumference L of the middle part of the axle housing 4 Perimeter L of axle housing straight arm 1 Perimeter L of round tubes at two ends of axle housing 2 The process steps of determining the forming method are as follows:
(1) Selecting an outer diameter d 0 Is a welded pipe of (1);
(2) The two ends of the tube blank are pushed and pulled for the first time to shrink the diameter: clamping the middle part of the tube blank on a three-way hydraulic press, synchronously reducing the two sides of the tube blank, and reducing the outer diameter of the diameter reducing part from d 0 Reduced to d 1 ，L 1 =2πd 1 The reduction ratio is L 1 / L 0；
(3) The two ends of the tube blank are pushed and pulled for the second time for reducing: clamping the middle part of the tube blank on a three-way hydraulic press, synchronously reducing the two sides of the tube blank, and reducing the outer diameter of the diameter reducing part from d 1 Reduced to d 2 ，L 2 =2πd 2 The reduction ratio is L 2 / L 1；
(4) Sealing ports are processed at two ends of the tube blank;
(5) First hydraulic bulging: the three-way hydraulic press uses a sliding bulging die with a back pressure punch to fill liquid into the tube blank and synchronously push the tube blank from two sides, so that the middle part of the tube blank is bulged, and the outer diameter of the middle section of the tube blank is increased to d 3 ，L 3 =2πd 3 To obtain axisymmetric cylindrical part, bulgingThe ratio is L 3 / L 0 =1.7-1.8 times, wall thickness reduction rate not exceeding 10%;
(6) The second hydraulic bulging: the three-way hydraulic press uses a sliding bulging die with a fixed die to fill liquid into the tube blank and synchronously push the tube blank from two sides, so that the middle part of the tube blank is bulged, and the perimeter of the middle section of the tube blank is increased to L 4 Obtaining a non-axisymmetric special-shaped piece; the bulging ratio is L 4 / L 3 1.25-1.3 times, the wall thickness reduction rate is not more than 10%, and the welded pipe weld joint is placed at the horizontal position of the front plane of the axle housing;
(7) Liquid filling press forming: the method comprises the steps of using a pressing die on a four-way hydraulic press, pressing a preformed tube blank from the upper direction, the lower direction, the front direction and the rear direction to obtain a front-flat rear-spherical axle housing semi-finished product, wherein the appearance of the product is consistent with that of a traditional stamping welding axle housing, and the product can be exchanged;
(8) Cutting off the additional plane front cover to obtain an axle housing product;
the hydraulic forming method of the axle housing of the drive axle adopts a high-strength welded pipe and does not need annealing, and comprises two bulging processes, wherein the first hydraulic bulging adopts a sliding hydraulic forming die with a back pressure punch, the second hydraulic bulging adopts a sliding hydraulic forming die,
the sliding type hydraulic forming die with the back pressure punch consists of 6 groups of rectangular back pressure punches, back pressure punch cylinders, fixed dies and sliding dies which are uniformly and symmetrically distributed in the radial direction;
a rectangular guide structure is arranged on the fixed mould to provide the guide and limit of the rectangular back pressure punch; providing a constant backpressure punch pressure F by a backpressure punch cylinder;
a rectangular groove is formed in the sliding die adjacent to the rectangular back pressure punch, and the rectangular back pressure punch is in clearance fit with the adjacent sliding die so as to solve the motion interference generated in the forming process of the rectangular back pressure punch and the adjacent sliding die;
the contact surface of the back pressure punch and the tube blank adopts a concave cylindrical surface, and the radius of the cylindrical surface is the radius of the inner cavity of the fixed die.
2. The hydroforming method for the axle housing of the drive axle, which adopts the high-strength welded pipe and does not need annealing, according to the claim 1, is characterized in that a sliding hydroforming die with a back pressure punch is adopted for the first hydraulic bulging, the sliding hydroforming die comprises a pair of sliding dies (11) and a pair of slotting sliding dies (17) which are symmetrically arranged from outside to inside, an upper die holder (19), an upper fixed die (111), a lower fixed die (115) and a lower die holder (116), the sliding dies (11) are connected with the slotting sliding dies (17), the outer end of an inner cavity of the slotting sliding die (17) is a tube blank sleeve interface end, and the sliding dies (11) are provided with hydraulic channels communicated with the interior of the tube blank; the slotting sliding die (17) is in sliding connection with a cavity formed by the upper die holder (19) and the lower die holder (116) through a guide post (113) and guide sleeve (114) structure; the upper fixed mould (111) and the lower fixed mould (115) are arranged at the axial middle position of the cavity, the upper fixed mould (111) and the lower fixed mould (115) are provided with a plurality of groups of rectangular guide grooves (117) and limiting steps (118) which are uniformly and symmetrically distributed in radial direction, a plurality of groups of rectangular back pressure punches (18) slide in the rectangular guide grooves (117) in radial direction and are limited by the limiting steps (118), the rectangular back pressure punches (18) are connected with a hydraulic system, and the inner end of an inner cavity of the slotting sliding mould (17) and a preformed deformation cavity of a tube blank formed by the plurality of groups of rectangular back pressure punches (18) are arranged.
3. The hydraulic forming method for the axle housing of the drive axle, which adopts the high-strength welded pipe and does not need annealing, according to claim 2, is characterized in that the inner cavity of the sliding die (11) is provided with a sealing sliding block (14) and a sealing pressing block (15), the sealing pressing block (15) is fixed at a connecting position between the sliding die (11) and the slotting sliding die (17), the sealing sliding block (14) is axially and slidably connected with the inner cavity of the sliding die (11), the inner cavity of the sealing pressing block (15) and the inner cavity of the slotting sliding die (17) form a tube blank sleeve joint, and a hydraulic tube hole of the sliding die (11) is communicated with the interior of the tube blank through a middle hole of the sealing sliding block (14).
4. The hydroforming method for a driving axle housing by adopting a high-strength welded pipe and needing no annealing according to claim 3, wherein the contact surface of the rectangular back pressure punch (18) and the tube blank is a concave cylindrical cambered surface, the radius of the cylindrical cambered surface is the inner cavity radius of the upper fixed mould (111) and the lower fixed mould (115), and the concave cylindrical cambered surface of the rectangular back pressure punch (18) forms a tube blank-like cylindrical cavity; the rectangular back pressure punch (18) is respectively connected with a back pressure punch cylinder (110), and the back pressure punch cylinder (110) is fixed on the upper die holder (19) and the lower die holder (116).
5. The hydroforming method for a transaxle axle housing using a high strength welded pipe and without annealing according to claim 4, wherein the second hydraulic bulging uses a sliding hydroforming die comprising a pair of second sliding dies (21), a pair of transition sliding dies (27) and a pair of intermediate sliding dies (29) which are symmetrically arranged from outside to inside, and a second upper die holder (213), a second upper fixed die (211), a second lower fixed die (215) and a second lower die holder (214), the second sliding dies (21) and the transition sliding dies (27) are fixedly connected, and the transition sliding dies (27) and the intermediate sliding dies (29) are slidingly connected with cavities formed by the second upper die holder (213) and the second lower fixed die holder (215) through a second guide post (28) and a second guide sleeve (210) structure; the second upper fixed mould (211) and the second lower fixed mould (215) are arranged at the middle position of the axial direction of the cavity; the outer end of the inner cavity of the transition sliding die (27) is a sleeve joint end of a preformed tube blank (212), a preformed deformation cavity of the preformed tube blank is formed by the inner end of the inner cavity of the transition sliding die (27), the inner cavity of the middle sliding die (29) and a die cavity formed by the second upper fixed die (211) and the second lower fixed die (215), and the second sliding die (21) is provided with a hydraulic channel communicated with the inside of the preformed tube blank (212).
6. The hydraulic forming method for the axle housing of the drive axle, which adopts the high-strength welded pipe and does not need annealing, according to claim 5, is characterized in that the inner cavity of the second sliding die (21) is provided with a second sealing sliding block (24) and a second sealing pressing block (25), the second sealing pressing block (25) is fixed at a connecting position between the second sliding die (21) and the transition sliding die (27), the second sealing sliding block (24) is axially and slidingly connected with the inner cavity of the second sliding die (21), the inner cavity of the second sealing pressing block (25) and the outer end of the inner cavity of the transition sliding die (27) jointly form a sleeve joint of the preformed tube blank (212), and the hydraulic tube hole of the second sliding die (21) is communicated with the inside of the preformed tube blank (212) through a middle hole of the second sealing sliding block (24).
7. The hydroforming method according to claim 6, wherein the cavity of the intermediate sliding die (29) and the cavity of the second upper die (211) and the second lower die (215) form a spherical-like preform cavity of the preform tube blank.
8. The method of hydroforming a transaxle housing using a high strength welded pipe and without annealing according to claim 7,
(1) Selecting a welded pipe, wherein the elongation of a welded pipe parent metal is not lower than 25%, and the elongation of a welding line is not lower than 17%;
(2) The two ends of the tube blank are pushed and pulled for the first time to shrink the diameter: clamping the middle part of the tube blank on a three-way hydraulic press and synchronously reducing the two sides of the tube blank, wherein the reducing ratio is L 1 / L 0 =0.85；
(3) The second push-pull diameter reduction is carried out on the two sides of the tube blank: clamping the middle part of the tube blank on a three-way hydraulic press and synchronously reducing the two sides of the tube blank, wherein the reducing ratio is L 2 / L 1 =0.84；
(4) Sealing ports are processed at two ends of the tube blank;
(5) The middle part of the tube blank is subjected to hydraulic bulging for the first time: the upper die holder is arranged on an upper vertical sliding block of the three-way hydraulic machine, and the lower die holder is arranged on the workbench; the left sliding die and the right sliding die are respectively arranged on a left sliding block and a right sliding block of the hydraulic press; the left and right sliding blocks of the hydraulic machine drive the left and right sliding dies to slide respectively, and the vertical sliding blocks of the hydraulic machine drive the upper die holder to move up and down;
firstly, placing a tube blank into a die, driving an upper die holder to move downwards by a vertical sliding block of a hydraulic press, and closing the die; the left and right sliding blocks of the hydraulic press respectively drive the sealing sliding blocks, the sealing pressing blocks, the left and right sliding dies to move together so as to seal two ends of the pipe blank; when the distance between the slotting sliding die and the upper fixed die is 180mm, the left and right sliding blocks of the hydraulic press stop moving; the rectangular back pressure punch clamps the tube blank under the action of the back pressure punch cylinder; under the action of a back pressure punch cylinder, the 6 groups of rectangular back pressure punches are guided by rectangular grooves on the upper fixed die and the lower fixed die, and back pressure F is applied to the outer surface of the tube blank;
the hydraulic system loads a curve, the inside of the pipe blank is filled with liquid and pressurized P, and meanwhile, the back pressure punch cylinder applies radial back pressure counterforce F to the outer surface of the pipe blank through the rectangular back pressure punch; the left and right sliding dies of the hydraulic press synchronously advance from two sides until die assembly is completed, so that the middle part of the tube blank is expanded, and the expansion ratio is L 3 / L 0 =1.79; the first hydraulic bulging is similar to a cylinder;
(6) The second hydraulic bulging of the middle part of the tube blank: the second upper die holder is arranged on an upper vertical sliding block of the three-way hydraulic machine, and the second lower die holder is arranged on the workbench; the left and right second sliding dies are respectively arranged on the left and right sliding blocks of the hydraulic press; the left sliding block and the right sliding block of the hydraulic machine drive the left sliding die and the right sliding die to slide respectively, and the vertical sliding block of the hydraulic machine drives the second upper die holder to move up and down;
firstly, placing a tube blank into a die, driving a second upper die holder to move downwards by a vertical sliding block of a hydraulic press, and closing the die; the left and right sliding blocks of the hydraulic press respectively drive the second sealing sliding block, the second sealing pressing block, the left and right second sliding dies to move together so as to seal two ends of the pipe blank; when the interval between the sliding die and the second upper fixed die is 25mm, the left and right sliding blocks of the hydraulic press stop moving;
the loading curve of the hydraulic system is used for filling liquid and pressurizing P into the pipe blank; the left slide block and the right slide block of the hydraulic press synchronously advance from two sides until the die assembly is completed, so that the middle part of the tube blank is swelled, and the swelling ratio is L 4 / L 3 =1.27, resulting in a non-axisymmetric spheroidal profile;
(7) Liquid filling press forming: using a pressing die on a four-way hydraulic press, wherein the internal pressure of a tube blank is kept to be constant at 20MPa, and pressing the preformed tube blank from the upper direction, the lower direction, the front direction and the rear direction, and after the pressing is finished, keeping the shaping pressure to be 60MPa, so as to obtain a front-flat rear-spherical axle housing semi-finished product;
(8) And cutting off the additional plane front cover to obtain the axle housing product.
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| CN108202098B (en) * | 2018-03-02 | 2023-04-11 | 济南大学 | Internal high pressure sealing push head |
| 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 |
| CN113385605B (en) * | 2021-05-10 | 2023-08-04 | 中航西安飞机工业集团股份有限公司 | Liquid filling forming method for large-bow high multi-cavity thin-wall open-pore inner skin |
| CN114433707A (en) * | 2021-12-22 | 2022-05-06 | 唐山学院 | Die for hydraulic bulging of embedded modular automobile axle housing pipe parts and machining method thereof |
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