Author: Jiangsu Sunway Group Co., Ltd. Aihua Yancheng Institute of Vehicle Engineering, Jiangsu University, Zhang Rui Yan Ping
The starter shaft of the automobile starter is one of the key parts of the starter. It is mainly used for planetary gear transmission. Therefore, it must have the characteristics of impact resistance, fatigue resistance, light weight and high torque transmission. It adopts traditional processing methods, low efficiency and cost. High, and inherently poor quality, far from meeting the volume requirements of the growing automotive manufacturers and aftermarket. Through repeated process tests, analysis and research, we have developed a high-efficiency precision forming technology and process method for automotive deceleration shafts. This process is in line with China's high-efficiency, low-consumption, high-quality industrial policy and has been approved by domestic related starter manufacturers. Welcome, achieved significant social and economic benefits.
Process analysis
Figure 1 Starter deceleration shaft
The starter deceleration shaft studied in this paper is the workpiece of a car starter. As shown in Figure 1, the upper part is the involute internal gear, the lower part is the transmission rod with the helical spline, and the coaxiality of the internal gear and the transmission rod. The requirements are higher. In order to maximize the production efficiency and reduce the speed reduction shaft to meet the requirements of machining accuracy, we believe that precision forming technology can be used to replace the traditional cutting process. Since the internal gear of the reduction shaft itself has to bear a large instantaneous bearing capacity and at the same time has a centering effect, its coaxiality and mechanical strength are required to be high, so that the plastic forming is relatively difficult, and an effective process is required. Measures. According to the structural characteristics of the parts, we determined that the process flow of the deceleration shaft is: blanking → stripping → spheroidizing annealing → shot blasting → phosphorus saponification → positive extrusion → upsetting → spheroidizing annealing → shot blasting → phosphorus saponification → reducing diameter Extrusion 1→ Reduced diameter extrusion 2 → Shot blasting → Internal tooth forming → Reduced diameter extrusion (standby) → Finished product.
2. Mold design and processing
(1) Calculation of extrusion force The extrusion force is the basis of mold design and an important basis for the selection of mold materials and extrusion equipment. The maximum extrusion force calculated according to the empirical formula P = pF is approximately 6350kN, and according to the nomogram ( Graph algorithm) The results obtained by the method are approximate.
(2) Mold design and processing Since the precision of precision-formed parts depends on the precision of the forming die, not only the reasonable forming process plan should be formulated, but also the structural characteristics of the parts and the precision requirements of the parts. Considering the subsequent machining and other matters, the designed mold not only requires a simple and practical structure, but also is easy to replace, and at the same time, it is easy to process. To this end, we have designed a set of simple and durable punch and split combination die after carefully determining the precision forming process parameters, which not only ensures the machining accuracy of the mold but also saves the mold material.
According to the mechanical analysis of the precision forming process, we found that: The die is almost subject to the full pressing force, and the crack is the first to cause the mold to break. Therefore, based on various factors, we have designed a set of longitudinally split combined prestressed female molds. The combined die can disperse the pressing force between the stress rings of each layer to avoid crushing failure due to stress concentration. The mold diagram is shown in Figure 2. In order to meet the requirements of long life and high precision of the mold, the mold needs to use a mold material with high strength, wear resistance and small deformation. To this end, we use the new special mold steel material YXR3 to make the lower core, punch and punch sleeve, 65Nb, 40Cr to make each layer of stress ring.
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