Study On Spinning Thickening Forming Process Of Double Mass Flywheel Drive Plate

Nowadays,resource scarcity is becoming an important issue that motivates many researches and manufacturers towards lightweight design of components,especially for the automobile industry.The concept of lightweight design mainly concerns the use of light materials and high-performance structures.Double mass flywheel drive plate,featured by thin plates and thick rims,is the key component connecting automobile engine and gearbox.Traditional forming processes of this part are casting,welding and stamping-forging.All these methods reduced the mechanical properties and raised the manufacturing cost.With the superiority of low cost and high mechanical properties,spinning thickening becomes an ideal strategy for forming such part with thin plate and thick rim.Based on the structure analysis of double mass flywheel drive plate,the required forming steps and the different size of roller groove in each step were calculated.Thus,the forming dies design,forming condition of plate spinning forming and the reasonable range of technological parameter were determined.On the basis of these,the forming process scheme of spinning forming was worked out.The double mass flywheel drive plate forming process was used to study the formation of multi-step spinning thickening process by the Simufact software.Based on the analysis of spinning thickening deformation,the finite element model of spinning thickening was established.According to the simulation result,the process of plate spinning thickening could be divided into three stages: the first stage was the outer edge of plate contact with the bottom of roller groove where the elastic deformation of the metal occured;the second stage was the outer edge of plate gradually thickened where the plastic deformation of metal occured;the third stage was the end of the forming process where the flash was produced.In the whole process,the radial force was the largest,the shear force was the second and the axial force was the least.Based on the simulation result,the influence of the process parameters,such as roller feed speed and friction coefficient,on the quality of plate spinning thickening were analyzed.From the perspective of plastic mechanics,the influence of spinning gap on the forming quality of plate was analyzed.It was found that pit,flash,hump and depression were the dominant forming defects that influence the surface quality and performance of the parts because of the unreasonable range of spinning gap.According to the control theory offorming defects,the measures to avoid the above defects were proposed,which provided guidance for the actual production.Based on the grey system theory,the roller feed speed,friction coefficient and rotational speed were independent variables,and the forming load and the thickness of the plate were the objective function.Through the calculation of the correlation coefficient and the correlation degree,the optimal combination of the multi-objective optimization forming process parameters was obtained that the roller feed speed was 1mm/s,the friction coefficient was 0.05,and the rotational speed was 250r/min.Combined with the optimization results and the forming defect control scheme,a physical experiment was carried out on the CDC-4S80 spinning machine,and a group of thickened parts with good forming quality were manufactured.