Effects Of Straight Arm Part Geometrical Parameters On Performance Of Buiging-pressing Axle Housing

Drive axle housing is an important bearing part of automotive chassis,its performance is directly related to driving safety.With the progress of science and technology,and the hydraulic bulging technology matures lately,the bulging-pressing axle housing’s stiffness,strength and fatigue life has obvious advantages,compared to the traditional stamping welding technology.At present,the study on thickness of axle housing are all focus on overall wall thickness.Benefit from the advancement of pushing-drawing necking technology,the bulging-pressing axle housing can only change the thickness of straight arm in a certain range.By using the method of finite element simulation and experimental verification,regard the wall thickness and the transition radius of straight arm part geometrical parameters as the research objects,to provide reference and basis for designing and manufacturing of bulging-pressing axle housing in the future.This paper main study on the kind bulging-pressing axle housing of pushing-drawing necking technology,analyzed the bending stress of axle housing in the largest vertical force conditions,researched the stress condition of the section where seat of steel spring is set,the transition fillet section and the middle part of axle housing seperately.Get the on local stress of drive axle housing that two straight arm geometrical parameters caused by theoretical analysis.First,build the 3D model of initial tube and accessories of axle housing with UG&CATIA.Then mesh them by using Hypermesh,simulate the forming process of bulging-pressing axle housing by using Abaqus,and set up multiple CAE models that under maximum vertical force conditions with different straight arm wall thickness and different transition radius.Carry on the static analysis to get the stress and deformation analysis result of axle housing,and analyzed the influence that straight arm wall thickness and transition radius have on the stiffness,strength of axle housing and the stress of the key parts.Import the analysis results with residual stress into the software MSC.Fatigue and the fatigue life of he bulging-pressing axle housing with different straight arm wall thickness and different transition radius is simulated.Research the influence rule that twogeometrical parameters of straight arm part have on the fatigue life,and the fitting relation between fatigue life and the straight arm wall thickness and the transition radius is obtained.Combined with the actual production and design,reasonable selection of two geometrical parameters are put forward,and illustrated the necessity of the research in the lightweight feild.Finally,the bench test of the bulging-pressing axle housing sample is carried on the and the responsibility of the research methods is proved.