胀压成形重型货车桥壳设计及扭转工况性能分析

doi:10.19562/j.chinasae.qcgc.2023.03.015

摘要/Abstract

摘要：

重型货车桥壳尺寸大、承载重，桥包部分受力复杂，在开发试验及工程应用中存在开裂现象。本文中提出了无缝钢管胀压成形的重型货车桥壳设计方法，给出了胀压成形工艺流程；设计并试制出1∶1的轴荷11.5 t重型货车桥壳样件，通过胀压成形过程的有限元模拟，揭示了桥壳的壁厚变化以及后盖过渡圆弧面的应力分布规律，揭示出桥包的变形强化系数达到1.37~1.61。通过在桥壳样件上推力座施加65 kN纵向力的扭转工况静强度模拟及试验，揭示出桥包部分的切向应变和法向应变最大为317με、每米轮距的最大纵向变形小于0.91 mm，并给出了桥包前平面高出两侧宽度、无缝钢管壁厚的设计依据。基于实车采集载荷谱下进行扭转工况的疲劳试验，胀压成形桥壳样件经过5个阶段共计141.9万次的循环，仍保持完好未失效。研究结果表明，无缝钢管胀压成形的重型货车桥壳质量轻、强度刚度高，为彻底解决桥包的失效问题提供了重要参考。

关键词: 重型货车, 胀压成形, 桥壳设计, 扭转工况, 性能分析

Abstract:

The axle housing of heavy-duty truck has large dimension， and high load-carrying capacity， and the stress on the axle housing cover part is complex. There is cracking phenomenon in the process of development test and engineering application. The design method of heavy-duty truck axle housing by seamless steel pipe bulging forming is proposed in this paper， and the process flow of bulging forming is given. The axle-housing sample of 1：1 axle load with load of 11.5 tons is designed and trial-produced. Through the finite element simulation of the bulging forming process， the changes of the wall thickness of the axle housing， as well as the stress distribution law of the transition arc surface of the rear cover are revealed， which shows that the deformation strengthening coefficient of the bridge package reaches 1.37~1.61. Through the static strength simulation and test under the torsion condition with a 65 kN longitudinal force applied on the upper thrust rod support of the sample， it is revealed that the maximum tangential strain and normal strain of the axle housing are 317με， with the maximum longitudinal deformation per meter of wheelbase less than 0.91mm. Moreover， the design basis for the front plane width of the bridge package higher than both sides and the wall thickness of the seamless steel pipe is given. Based on the load spectrum collected from the real vehicle， the fatigue test under the torsional condition is carried out and the axle housing sample remains intact after five stages of 1.419 million cycles in total. The research results show that the axle housing of heavy-duty truck by seamless steel pipe bulging forming has light weigh， high strength and stiffness， which provides an important reference for solving thoroughly the failure of axle housing.

Key words: heavy-duty truck, bulging forming, design of axle housing, torsion condition, performance analysis

王连东,宋希亮,李莹莹,崔亚平,武婷. 胀压成形重型货车桥壳设计及扭转工况性能分析[J]. 汽车工程, 2023, 45(3): 477-488.

Liandong Wang,Xiliang Song,Yingying Li,Yaping Cui,Ting Wu. Design and Performance Analysis Under Torsion Condition of Bulging Forming Axle Housing of Heavy-Duty Truck[J]. Automotive Engineering, 2023, 45(3): 477-488.

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典型点	ST₁	ST₂	ST₃	ST₄	XT₁	XT₂	XT₃	XT₄	GS	GL
X坐标/mm	-93	-93	177	177	-283.5	-283.5	363.5	363.5	-283.5	363.5
Y坐标/mm	-34	46	-34	46	-72.5	72.5	-68.5	68.5	0	0
Z坐标/mm	235	235	183	183	-25	-25	-25	-25	111	80
流动应力/MPa	471.47	501.42	474.17	471.99	492.58	491.21	529.37	517.88	530.88	544.52
强化系数	1.37	1.45	1.37	1.37	1.43	1.42	1.53	1.50	1.54	1.58
残余应力/MPa	144.20	183.55	144.90	150.22	185.01	213.89	185.16	206.03	133.26	141.50

零件名称	材料	密度ρ/（kg·m^-3）	弹性模量E/GPa	泊松比μ
桥壳管件、加强圈、衬环	Q345B	7 800	210	0.3
半轴套管、推力座、法兰盘、工装	40Cr	7 850	209	0.27
板簧座	ZG230-450	7 830	211	0.31
主减速器壳	QT450-10	7 300	173	0.3

测量点	C₀	C₄₅	C₉₀	C₁₃₅	ST₁	ST₂	ST₃	ST₄	XT₁	XT₂	XT₃	XT₄	GS	GL
切向	56	185	-15	149	-214	298	-97	75	4	-9	6	-12	50	73
法向	49	110	-174	-117	-231	249	-256	197	-35	42	83	-74	-72	-62

加载顺序	预载荷/kN	载荷赋值/kN	循环次数/ 万次	上推力座位移量/mm
1	0	21	61	0.92
2	0	30	61	1.45
3	5.5	45	16	1.93
4	1.6	53	1.9	2.34

初始管坯壁厚	C₄₅点变形	C₉₀点变形	C₁₃₅点变形
10	2.40	2.79	2.49
11	1.38	1.67	1.40
12	1.21	1.39	1.25