The Study Of Deformation Process Of Pressing Progress Of The Front-Flat And Rear-Globular Axle Housing

The bulging-pressing craft is a new technology to product axle housing, which obtain a certain shape preforming tube by necking the end portion of initial tube and bulging the middle part of initial tube, and manufacture axle housing with additional front-cover by pressing the preforming tube. The bulging-pressing axle housing has advantages of weldless, light weight and good strength and stiffness, the shape of additional front-cover of the current process is spherical crown, which has not high enough material utilization, more processes and high cost during the actual production, this paper designs the axle tube with the shape of front-flat and rear-globular, and study on the craft of pressing progress, in order to improve material utilization, reduce progress and cut down the cost of the actual production.For the axle housing of front-flat and rear-globular, the deformation progress of the typical cross section and longitudinal section of preforming tube during the pressing progress is analyzed, reveal the law of metal flow is revealed, and the possible problem of the sunken front platform and the cracked rear-cover with its influence factor is pointed out.For the 5t rated loading bulging-pressing axle housing, the shape of the preforming tube is designed, the relationship of the rear cover radius R1 of the dome part and the rear cover radius R0 of axle housing is given out,R₁=K₁R₀, and the relationship of the front cover radius R2 and the rear cover radius R1 of the dome part is given out,R₂=K₂R₁, K₁ and K₂ define respectively the rear cover radio and the front cover radio.The preforming tube with different K₁ and K₂ is designed, the simulation of the bulging progress is done, the ranges of K₁ and K₂ are curtained initially, based on whether the tube is cracking or wrinkling during deformation. For the preforming tube within this ranges, the simulation of the pressing progress is done, the reasonable ranges of K₁ and K₂ is further curtained, based on whether the rear cover is cracking or the front platform is sunken during deformation.Based on a best shape of the preforming tube, a process flow diagram of 5t axle housing of the front-flat and rear-globular is designed at first, the simulation of the progress of necking, bulging and pressing for the initial tube is done, and the distribution law of thickness is given out. This paper evaluate the two process flow diagrams of the front-rear globular axle and the front-flat and rear-globular axle with scoring method by establishing a evaluation modal with evaluation index of formability, the number of crafts, cost of production and the performance.