Research And Application Of Torque Converter Turbine Forming Process

Stamping Welding Hydraulic Torque Converter is the core component of hydraulic automatic transmission,turbine is the key component of torque converter,and the forming quality of turbine is one of the core factors affecting the performance of torque converter.At present,there are mainly two ways to rivet the turbo of the Stamping Welding Hydraulic Torque Converter,one is manual riveting,and the other is to use a special roller riveting machine to rivet the turbo.There are many limitations in both riveting processes.Manual riveting is difficult to guarantee the forming accuracy of the turbine;the roll riveting machine is a special equipment with a long development period,however,in the process of designing new torque converter products,a prototype needs to be manufactured quickly to verify the performance of the torque converter.Therefore,the purpose of this paper is to develop a set of rapid forming process for stamping welding torque converter turbine,to realize the high-precision riveting and forming of turbine assembly,and to study the influence of forming process parameters on the dimensional accuracy of turbine.Taking the Stamping Welding Hydraulic Torque Converter turbine as the research object,we combine experimental and numerical simulation methods to carry out blade lug structure design,blade stamping and forming and rebound simulation,turbine assembly roll riveting forming simulation,roll riveting device design,roll riveting process parameter optimization and application,etc.The specific research is as follows.(1)Numerical simulation of turbine blade stamping and forming.The virtual assembly analysis was carried out,and the structural unfolding design of the turbine blade trunnion was carried out according to the theoretical design model of the turbine blade.One-step inverse algorithm is used to initially determine the blank size of the turbine blade,establish the stamping and forming simulation model of the blade,carry out the stamping and forming simulation analysis,obtain the stamping and forming results of the blade,and clarify the feasibility of the stamping process.(2)Turbine blade rebound compensation and mold design.Numerical simulation of stamping rebound and rebound compensation calculation were carried out to predict the amount of rebound of the turbine blade in view of the insufficient plastic forming of the turbine blade.The die surface compensation method is used to control the stamping rebound of the blade,and the blade stamping die is designed to produce the turbine blade with dimensional accuracy.(3)Roll riveting forming process and equipment design and development.Using the finite element analysis method,we carried out the simulation analysis of roll riveting forming for the turbine assembly,studied the influence of roll riveting parameters on the forming accuracy,and determined the optimized process parameters.According to the motion characteristics of the vertical lathe,the roll riveting forming equipment of the turbine was developed,and the roll riveting processing of the turbine sample was completed on the vertical lathe to verify the feasibility of the roll riveting process.(4)Analysis of the dimensional accuracy of the assembly and verification of process feasibility.By using three-dimensional optical scanning method,we innovatively designed the measurement and characterization methods for the angle distribution of the blade grille and the deviation of the blade grille height,and verified the accuracy of the turbine assembly by roll riveting.