Analysis of Bulging-pressing Forming Mechanism and Determination of Internal and External Pressure Application Criteria for Large and Complex Shape Automobile Axle Housing Pipe

doi:10.3901/JME.2022.04.062

Abstract

Abstract: Bulging-pressing is a new technology for manufacturing large-size and complex automobile axle housing pipe, which has good formability and low internal pressure. However, the forming mechanism is not clear and there is no definite method to determine the internal and external pressure. The technology is introduced and the process of hydro-pressing of preformed tube blank is analyzed. The forming mechanism of small fillet and large arc area of cross section is revealed, and the expressions of stress, internal pressure and external pressure are derived. The application criteria of internal pressure and external pressure are put forward, and the calculation formula of initial internal pressure and the expression of pressing mode are given. The finite element analysis of the bulging-pressing of a 10 t axle housing pipe was carried out, and the results show that the stress state and changing trend of small fillet and large circular arc are consistent with the theoretical analysis. The variation law of shear stress is revealed, and the optimal internal pressure coefficient nf and pressing coefficient ks are obtained. The engineering tests were carried out, and the pressing force of molds, the small fillet size and the wall thickness of the large arc were measured. The results show that the finite element simulation values under the same conditions are consistent with the experimental results, the maximum deviation is 6.81%.

Key words: automobile axle housing, hydro-pressing, shear stress, pressing method, application criteria

CLC Number:

TG316

WANG Xiaodi, WANG Liandong, JIN Miao, LIU Heng, XU Shiwang. Analysis of Bulging-pressing Forming Mechanism and Determination of Internal and External Pressure Application Criteria for Large and Complex Shape Automobile Axle Housing Pipe[J]. Journal of Mechanical Engineering, 2022, 58(4): 62-71.

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