Numerical study on the applicability to manufacturing of contact-stress-optimised shaft-hub connections joined by lateral extrusion
Numerical study on the applicability to manufacturing of contact-stress-optimised shaft-hub connections joined by lateral extrusion
复制标题
横向挤压连接的接触应力优化轴毂连接制造适用性的数值研究
DOI：
10.1051/mfreview/2020016
复制
发表时间：
2020
影响因子：
2.5
通讯作者：
Ulrich
中科院分区：
文献类型：
--
作者：
Meissner;R.J.-P;Liewald;Ulrich
通过至少一个部件的塑性变形连接（例如通过侧向挤压连接）的轴-毂连接可以满足当今对低制造成本的高功率密度的矛盾要求。与传统的制造方法相反，这里不需要轴和毂的紧密制造公差，因为轴在过程期间形成在毂中以产生组合的摩擦和强制锁定连接。然而，塑性变形通常会导致接触应力的不均匀分布，这会导致负面影响，例如增加轮毂应力和变形，以及降低连接的传输能力。为了克服这种影响，Ulrich等人（2019）[]开发了一种用于塑性应力轴-轮毂连接的迭代设计方法，其中接触应力分布受到轮毂接触表面轮廓的影响。尽管如此，该工艺中的一个主要挑战是应力分布对轮廓变化的高度敏感性，特别是在连接的边缘区域，这意味着这里也存在对严格制造公差的依赖性。因此，进行了调查，以确定在何种程度上的偏差在制造过程中的组件，在工具质量和连接过程中通过横向挤压影响所产生的接触应力。为了实现这一目标，进行了数值研究，并对所得的接触应力分布的影响进行了分析。最后，制造精度和工艺限制的建议，以确保可制造性，使技术转移到工业应用，涉及轴毂连接加入横向挤压。
Shaft-hub connections, which are joined by plastic deformation of at least one component (e.g. joining by lateral extrusion), can meet today's contradictory requirements for high power densities with low manufacturing costs. As opposed to classical manufacturing methods, the tight manufacturing tolerances of shafts and hubs are not required here since the shaft is formed in the hub during the process to generate a combined frictional and positive-locking connection. However, plastic deformation generally results in an uneven distribution of contact stress, which causes negative effects such as increased hub stress and deformation, as well as the reduced transmission capacity of the connection. To overcome this effect, an iterative design approach for plastically stressed shaft-hub connections was developed in Ulrich et al. (2019)[], in which the contact-stress distribution is influenced by contouring of the hub contact surface. Nonetheless, one major challenge in this process is the high sensitivity of the stress distribution to contour changes, particularly in the edge area of the connection, meaning that a dependency on tight manufacturing tolerances is present here, too. Therefore, an investigation is conducted to determine the extent to which deviations in the manufacturing process of the components, in the tool quality and during joining by lateral extrusion influence the resulting contact stress. In order to achieve this goal, numerical investigations are carried out, and the effects on the resulting contact-stress distribution are analysed. Finally, recommendations for manufacturing accuracy and process limits are derived in order to ensure manufacturability and enable the transfer of technology to industrial applications involving shaft-hub connections joined by lateral extrusion.
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