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针对汽车花键轴锻造成形难度大、废品率高、材料利用率低、成本高等问题,提出了一种改进的花键轴锻造工艺。采用Deform-3D软件模拟了花键轴改进工艺的锻造过程,取消了聚集模体,把预锻凹模体的过渡腔轴向截面改为圆锥形结构,确保预锻成形的可靠性。预锻凸模体和终锻凸模体采用分体组合式结构,方便更换;连接块与连接板之间采用楔形块和楔形孔配合,便于拆装;凹陷部和凸圆环配合确保冲压部和连接部之间定位精准、可靠。结果表明,采用改进后锻造工艺生产出的花键轴锻件不仅满足力学性能要求,而且材料利用率提高2%,废品率下降2%,单件成本下降1.4元左右。
Aiming at the problems of forging forming of automobile spline shaft, high rejection rate, low material utilization and high cost, an improved spline shaft forging process is proposed. Deform-3D software was used to simulate the forging process of the spline shaft improvement process. The accumulation of the mold body was canceled. The axial cross section of the transition cavity of the pre-forging mold body was changed to a conical structure to ensure the reliability of the preforming. The forging punch body and the final forging punch body are in a split combination structure for easy replacement; the wedge block and the wedge hole are used between the connection block and the connection plate to facilitate disassembly and assembly; the concave portion and the convex ring ring cooperate to ensure the stamping portion And the connection between the positioning accuracy and reliability. The results show that the splined shaft forging produced by the improved forging process not only meets the mechanical performance requirements, but also increases the material utilization rate by 2%, the rejection rate by 2% and the unit cost by about 1.4 yuan.