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运用DEFORM 3D软件对高强度27MnCr5钢变速器传动轴冷锻成形进行了有限元仿真,获得了始锻和终锻的应力和应变。对始锻、终锻下的冷锻传动轴试样进行了拉伸和疲劳试验,获得了传动轴抗拉强度和疲劳应力值,并与仿真结果进行了对比分析。结果表明:随着冷锻成形的进行,传动轴等效应力、等效应变、极限抗拉强度、张紧应力幅值、张紧平均应力、弯曲应力幅值、弯曲平均应力都逐渐增加;有限元仿真应力值与试验应力值的最大相对误差为3.41%,说明仿真分析是比较准确和可靠的。
DEFORM 3D software was used to simulate the cold forging forming process of the high strength 27MnCr5 steel transmission shaft. The stress and strain of initial forging and final forging were obtained. Tensile and fatigue tests were carried out on cold forged drive shaft samples under initial forging and final forging. Tensile strength and fatigue stress of shaft were obtained and compared with simulation results. The results show that the equivalent stress, the equivalent strain, the ultimate tensile strength, the tensile stress amplitude, the average tensile stress, the bending stress amplitude and the mean bending stress increase gradually with the cold forging forming. The maximum relative error between meta-simulation stress and experimental stress is 3.41%, which shows that simulation analysis is more accurate and reliable.