Research On Spinning Forming For Complex Structure Multi-wedge Pulley On Automotive

The multi-wedge pulley have high temperature resistance and high oil resistance,and it’s stable outputing,low transmission noise and also can absorb mechanical transmission shock and vibration during mechanical transmission.So multi-wedge pulley is widely used in automobile engine transmission trains.Traditional forming processes manufacturing multi-wedge pulley are have a lot of forming defects and low material utilization,it can not meet the high performance manufacturing of automobile multi-wedge pulley.But Spinning forming is a near net shape forming technology,it can significantly improve material utilization and ensure part forming quality and precision.So a multi-steps pinning forming becomes an ideal strategy for forming complex structure multi-wedge pulley.Based on characteristics and forming difficulties of complex structure multi-wedge pulley,Multi-steps spinning forming scheme was designed and parametric analysis of the rotating wheel.Also the material parameters,meshing,contact relationships and boundaries during the establishment of the finite element model are defined.Finally,a multi-steps spinning forming scheme with complex structure and multi-wedge wheel was successfully defined.Systematic analysised the multi-steps spinning forming process of complex structure multi-wedge pulley.Analyzed the local thickening phenomenon of the outer edge of the blank,the metal flow law,the stress and strain state during the outer edge of the blank in the four-steps spinning process.It is found that the outer edge metal is affected by the arc surface of the curved wheel and the inclined surface to produce a significant thickening phenomenont in the spining bending forming process,and the outer edge of the blank is formed an arc shape and the local thickness can reached4.85 mm.The side ribs and outer ribs are formed by the flattening wheel During the spinning flattening forming process and successfully avoids not full filling of the ribs.Finally,the tooth formation of the part is completed by three or four steps spinning forming process.It’s explored the influence of different process parameters on the spinning forming quality of this part.Obtained a conclusion:the smaller friction and the smaller feed rate are beneficial to improve the lateral external rib filling quality,reduce the depth of the folding,improve the stress distribution and reduce the spining forming load.Based on the response surface method,the parameters of multi-steps spinning forming process for complex structure multi-wedge pulley are optimized.And analyzed the influence of each design variable on the target variable by the response surface model and the visual graph.the optimal combination of the multi-objective optimization forming process parameters was obtained that the velocity of rotary wheel is 0.50mm/s,the rotation of Mandrel is 100 rpm,and the friction between the rotary wheel and the blank is 0.05.And the feasibility of the optimal process parameter scheme was verified by finite element simulation and physical experiments.Finally,the multi-steps spining forming of complex structure multi-wedge pulley was completed and the full process optimization technology are created.