Research On Axial Loading Performance And Forming Springback Of Integral Corrugated Sheet

The corrugated sheet is a key component of the driven plate of the automobile clutch.It is located between the friction plate and the driven plate in the driven plate assembly.It mainly plays the role of smoothing the coupling of the clutch and reducing the impact of the clutch during operation.At present,the corrugated sheet is divided into integral type and monolithic type,the structural difference of the two wave forms determines that the integral wave form has a more stable loading performance than the single wave form,but at the same time,the processing technology and precision requirements of the integral corrugated sheet are relatively high.In view of the current situation of relatively little research on integral corrugated sheet,This work combines theoretical analysis,finite element simulation and experimental comparison to systematically analyze the loading performance,forming springback process,forming method and mold structure design of the integral corrugated sheet,the specific research content and main analysis results are as follows:(1)Take the given model 65 Mn integral corrugated sheet as the research object,based on the ABAQUS finite element analysis software,through the adjustment of the key parameters of the corrugated sheet structure,the load curve generated by the axial load of the friction plate is simulated and constructed.The result shows: both the smaller thickness of the corrugated sheet and the larger forming height can shift the inflection point(the point of steep slope change)of the loading curve to the right.This shows that as the thickness and forming height of the corrugated sheet increase,the actual load range decreases,and a smaller pressure can cause the corrugated sheet to deform;the effect of the change of the fillet radius on the loading curve is not obvious.In addition,a loading experiment was carried out on the corrugated sheet forming sample by a tensile tester,the result is basically consistent with the numerical curve of simulation analysis after optimization of structural parameters.(2)The finite element analysis software of ABAQUS was used to simulate and analyze the forming and springback process of a single sub-piece of the integral corrugated sheet.The results show that the forming height of the integral corrugated sheet decreases with the increase of the mold gap and fillet radius,and increases with the increase of the sheet thickness.Among them,the comparative analysis of the forming simulation results and the key parameters of the product part drawing shows that when the fillet radii in the key parameters of the mold structure are 18 mm,17mm,17 mm,19mm,the thickness of the wave sheet blank is 0.6mm,and the mold gap is set to at 0.6mm,an integral corrugated sheet that meets the design requirements can be obtained.Based on the above-mentioned key parameters,a single sheet forming die was designed and processed.According to the actual stamping test results,the forming height of each sub-sheet of the integral corrugated sheet is within the design range of 0.8-1.1mm,which meets the product requirements.(3)Using ABAQUS software to analyze the forming height value of each sub-sheet of the integral corrugated sheet under the simultaneous forming of multiple sub-sheets,comparing this result with the simulation result of monolithic sheet forming in the research content(2),it is found that using multiple sub-sheets to form in one step,theoretically it can also ensure that the forming height of each sub-sheet is within the design requirements of an integral corrugated sheet.Combining the simulation results,a multi-piece one-step forming mold diagram was designed.In addition,in order to improve the processing quality and production efficiency of the integral corrugated sheet,this work also provides the structural design plan of the integral corrugated sheet multi-sub-sheet stamping progressive die,which aims to blank,shape and form the integral corrugated sheet.The punching and other processes are integrated into a set of molds,so as to achieve the goal of a single set of molds to continuously stamp the integral corrugated sheet in large quantities.