汽车铝合金轮毂生产工艺研究

汽车铝合金轮毂生产工艺研究

张　总1,2,张怀亮1

(1.中南大学机电工程学院,湖南长沙410075;2.长沙航空职业技术学院,湖南长沙410124)

摘　要:分析了汽车铝合金轮毂的优点、结构和性能,结合汽车轮毂研发和生产过程,给出了汽车铝合金轮毂的生产工艺。随着世界汽车轻量化进程的加快,国际汽车市场竞争日趋激烈,节能化、轻量化成

为我国汽车工业发展的必然趋势,目前轻合金轮毂主要为铝合金轮毂,镁合金轮毂尚处于起步阶段,而铝合金轮毂生产方法有了较大进步。因此,加强对汽车铝合金轮毂生产制造的研究是很有必要的。

关键词:轮毂;铝合金;生产工艺中图分类号:TG335.8文献标志码:A　　汽车轮毂是汽车上的重要零件,有实用性和装饰性两种作用,在国外,轮毂工业被誉为“时装化工业”,其品种繁多,形状复杂,尺寸精度要求高,因而如何采用快速有效的方法进行产品开发,是在实际生产中急待解决的问题。

于钢。成,平衡性能差,,铝合金轮毂,铝合金轮12%。

。车轮的热源由2部分产生,;二是轮胎与路面的摩擦。特别是高速行驶的情况下,车轮温度很高,增加了爆胎的危险性。铝合金轮毂的散温系数是普通钢铁轮毂的2～3倍,而且轮毂表面设计的结构特性有利于散热,即便在长时间行车中连续刹车的情况下,也能使车轮系统保持适当的温度,因此使用铝合金轮毂可减少积热,减少爆胎的机会,提高了安全性。

第4,美观。轮毂的美观程度对于汽车整车的形象有着很大的影响。现今的汽车轮毂设计是汽车造型设计中1个不可遗漏的重点,并且轮毂造型直接关系着汽车车身设计的品味和档次。因此,如何进行轮毂的造型设计,如何设计出有风格特色和审美情趣的轮毂成为轮毂制造厂和设计者们关心的问题。铝合金轮毂的生产工艺与钢轮毂不同,其外观设计精美,造型多样化,可以做到车毂合一,尽显完美,提高整车的审美观,而且还可以设计加工成各种花纹结构,通过表面处理形成不同的色泽或通过电镀形成镀层,最大限度地满足各类使用者的审美要求。1.2　汽车铝合金轮毂的结构分析

为了满足使用功能和市场的需求,铝合金轮毂在结构上有整体式和多件组合式等多种结构设计;在外观造型上有宽轮辐、窄轮辐、多轮辐、少轮辐等多种造型设计。出于安全的原因,在铝合金轮毂的外观造型和结构设计时必须要以满足安全和使用功能的要求为前提。对于普通乘用车而言,整体式铝合金轮毂足以满足其性能要求。

汽车轮毂的结构如图1所示,可分为轮辋和轮毂2个部分,具体各部分功能分析见图2所示。

1　,是一种、乘车的舒适。长期以来,钢制轮毂占据了汽车轮毂应用的主导地位。随着人们对汽车安全、环保、节能、舒适等方面要求的不断提高,以及铝制轮毂在设计与制造技术上的不断进步,虽然其应用历史不长,但发展速度很快,正逐步代替钢制轮毂成为最佳选择。20世纪70年代起发达国家开始大批量推广应用铝轮毂,铝轮毂成为铝合金在汽车上的第二个应用广泛的领域。1.1　汽车铝合金轮毂的优点生产先进合理的铝合金轮毂是汽车铝化与高性能化的主要内容之一。与其他材料相比,铝合金轮毂有以下优点:

第1,重量轻,节能降耗。铝轮毂与钢轮毂相比,重量可减轻30%～40%,减少了四轮的转动惯性,使汽车的加速性提高了,并相对减少了制动的能量需求,从而减少了油耗。通过实际实验测算,以奥迪轿车为例,铝合金轮毂重量减轻了39.5%,从起步加速到100km的速度需要的时间减少了0.3s;在车速为90～120km/h时,油耗减少约为0.05L/100km,在城市行驶时,可减少约为0.04L/100km,每10万公里可节约耗油40～50L。

第2,改善驾驶性能,驾乘更舒适。铝合金轮毂能够实现高精度和与轮胎的分离性,减小振摆与振动,改善车体重心,这因为铝合金的振动性能优于钢,而且铝合金轮毂采用数控设备加工,平衡性能优

种多样、生产成本较低等优点,所以铸造法仍是生产铝合金轮毂最普遍的方法,在目前全世界生产的铝合金轮毂中,铸造的占80%以上。其工艺方法有重力铸造、低压铸造、压力铸造和挤压铸造等。

2)锻造法锻造是铝轮毂应用较早的成形工艺之一,具有强度高、抗蚀性好、尺寸精确、加工量小等优点,一般情况其重量仅相当于同尺寸钢轮的1/2或更低一些。锻造铝轮毂的晶粒流向与受力的方向一致,其强度、韧性与疲劳强度均显著优于铸造铝轮毂。同时,性能具有很好地再现性,几乎每个轮毂具有同样的力学性能。锻造铝轮毂的典型伸长率为12%～17%,。通常,但承受,。另外,锻造铝轮,不但,结合牢靠,而且色彩也好。锻造铝轮毂的最大缺点是生产工序多,生产成本比铸造的高得多。

3)半固态模锻法

半固态模锻是锻造的一种,介于固态成形和液态成形之间的崭新工艺。零件在模内收缩较小,机械加工量减少,半固态模锻件表面平整光滑、内部组织致密,晶粒细小,力学性能高于压铸和挤压铸造件,成形不易裹气,宏观气孔和显微疏松比常规铸件中的少得多,成形温度低,模具寿命长等许多独特的优点。在国外主要应用在汽车铝合金零件制造方面,被称为21世纪新一代新兴的金属成形技术。国内对这种技术的研究起步较晚,实际应用得很少。

图1　汽车轮毂结构示意图

胎圈座—与轮胎的胎圈接触,支撑维持　　　　轮胎半径方向的轮辋部分。

轮辋—与车胎连接部分

轮　缘—保持并支撑轮胎方向的轮辋　　　　部分。

气门孔—安装轮胎气门嘴的孔。槽　底—为方便轮胎装拆,在轮辋上留

　　　　有一定深度和宽度的凹坑

偏　距—轮毂—辐—,支　　　　撑轮辋的车轮部分

图2　汽车轮毂的结构功能分析图

1.3　汽车铝合金轮毂的性能要求

铝合金轮毂的种类、结构较多,其要求因车种,车型而异,但强度与精度兼备是最基本的共同要求。通过市场调研得知,车轮毂应具备以下性能:

1)材质、形状和尺寸正确合理,能充分发挥轮胎的功能,与轮胎互换,具有国际通用性;2)行驶时,纵、横向振摆小,失衡量与惯性矩小;

3)在轻量化的前提下,具有足够的强度、刚度

2　汽车铝合金轮毂生产工艺的研究

2.1　汽车铝合金轮毂的设计开发流程

和动态稳定性;4)与轴、轮胎的可分离性好;

5)具有优良的耐久性;

6)其制造工艺能达到产品质量稳定、成本低、

随着家用轿车品种的增加和价格的下调,汽车正在成为当今中国老百姓消费的热点产品。对汽车

的要求也开始从实用和认知向汽车的审美功能过渡。人们不仅要求汽车的性能优良,驾驶操作方便,还要求汽车外观符合自己的审美品位和身份定位。然而,轮毂的美观程度对于汽车整车的形象有着很大的影响,如果企业没有自己设计开发轮毂的能力,是很难在市场上长久立足的。因此轮毂的设计开发是企业发展的关键所在,汽车铝轮毂进行设计开发的主要方法和流程如图3所示。2.2　汽车铝合金轮毂的生产工艺流程由于低压铸造是最基本和较经济的生产方法,所以目前低压铸造已成为铝合金轮毂生产的首选,

多品种、可大规模生产等要求。1.4　汽车铝合金轮毂的成形方法

目前铝合金轮毂的生产方法主要有铸造法、锻造法、冲压法和旋压法等。我国的铝合金轮毂制造仍以低压铸造为主,一些先进的制造工艺还未采用。但铝合金轮毂的制造技术在不断的发展,为了提高其性能,现在向挤压铸造(液态模锻)成形、半固态模锻成形方向发展的趋势。

1)铸造法

铸造法生产铝合金轮毂具有适应性强、花色品

图4　汽车轮毂生产工艺流程图

[参考文献]

[1]赖华清,范宏训.汽车铝合金轮毂的成形工艺[J].金属

成形工艺,2002(6)1

[2]沈俊.铝合金汽车轮毂及其生产工艺[J].有色金属加

工,2002(1)1

图3　汽车轮毂研发流程图

[3]蒋鹏,贺小毛,张秀峰.半固态成形工艺在汽车工业中的

日本的丰田汽车公司、东京轻合金制作所和美国福

特汽车公司等企业均采用此工艺生产铝合金轮毂,国内的铝合金轮毂制造企业也多数采用此生产工艺。通过分析获得高质量的汽车铝合金轮毂的生产过程,选用合理的生产工艺。如图4所示。

应用[J].汽车工艺与材料,1998(3)1

[4]王昕.铝合金汽车轮毂的生产方法[J].轻合金加工技

术,2001(4)1

3湖南省财政厅教育厅高校科研项目“CAD/CAM技术在

(编号为07D004)汽车轮毂模具加工中的应用研究”

3　结语

随着世界汽车轻量化进程的加快,国际汽车市

场竞争日趋激烈,节能化、轻量化成为我国汽车工业发展的必然趋势,目前轻合金轮毂主要为铝合金轮毂,镁合金轮毂尚处于起步阶段,而铝合金轮毂生产方法有了较大进步。因此,加强对汽车铝合金轮毂生产制造的研究是很有必要的

。作者简介:张总(19802),男,讲师,硕士研究生,研究方向为

机械设计及自动化。

收稿日期:2008年7月10日

责任编辑　吕德龙

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Abstract:Thispaperanalyzestheconditionofthealuminumfoilslabmaterial,theproductiontechnologyandequipmentlevel,andfindsoutthereasonthatcausesthecastingslabmaterialproducethedoublezeroaluminumfoilpinhole.Inthispaperthequantityofthedoublezeroaluminumfoilpinholegetseffectivelycontrolbyusingrelativecontrolmethodandlower“pinholedegree”ofthea2luminumfoiltoreachthetaskofimprovingthequalitystabilityofaluminumfoil.Thispaperanalyzesthereasonofpinholeexiting.Controlhasbeencarriedfromthesituationofaluminumfoilslabmaterial,equipmentlevel,rolledsurfaceroughnessandfilterpreci2sionofrollingoilandsoon,sothatthenumberofpinholeofdoub2lezeroaluminumfoilhasbeenreducedastheendbreakingrate.Keywords:zeroaluminum;;casting2rollingTheCauseandControlMethodofDoubleZeroAluminumFoilPinhole

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XUFei1,2,CHENLi2,GONGShuili2,LIXiaoyan1,YANGJing1,2(1.CollegeofMaterialsScienceandEngineering,BeijingUniversi2tyofTechnology,Beijing100022,China;2.BeijingAeronauticalManufacturingTechnologyResearchInstitute,Beijing100024,China)Abstract:Fromthelaserfillerwireweldingteststothe5A06alu2minumalloysheetof1.2mmthick,wefoundthattheimpossiblerealizationoftheeffectiveweldingprocessparametersbyusingla2serweldingwhentheweldingspeedislowcanberealizedbyfillingwiresothatgetthebetterdeeppenetrationweldingresult.Thereareonlyfewtinyblowholesintheweldingseam.Thispaperalsoanalyzestheweldingeffectandtheformingmechanismoftheblowhole.Thelaserweldingwithfillerwirecanincreasethelaserenergyabsorptionrateofthematerialsthroughaddingwires,tomaintaintherelativestabilityofthe“blowhole”,toimprovetheweldingseamformingbyusinglaserweldinginthelowerweldingspeed,thuscanrealizetheonesideweldinganddouble2sideshapeoftheweldingseam.Keywords:laserwelding;laserfillerwirewelding;5A06aluminumalloy;blowhole

Jie’an,LIUZhanfeng(P.O.Box242,Xi’an,Xi’an710065,China)

:Inrecentyears,withrapidprototypingtechnologydevel2opment,newrapidprototypingtechnologyhasbeenemerged.Di2rectwritingrapidprototypingtechnologyisanewrapidprototy2pingtechnologyanditsdevelopmentgetsmoreandmoreattention.Thispaperintroducestheprinciple,characteristicandapplicationofdirectwritingrapidprototypingtechnology.Nozzlebackpressuresystemisusedtocontroldropletsemitfromthenozzle,sochooseasuitablebackpressuredropletshasanimportantinfluenceonthenozzletoproduceuniformdroplet.Therefore,itisnecessarytode2signastableandreliablebackpressuresystem.Basedonthere2quirementofliquidsprayofdirectwritingrapidprototypingma2chine.Thispaperdesignsabackpressureliquidspraysystem.Keywords:directwritingrapidprototyping;backpressuresystem;design

B2DirectWritingRapidResearchontheServoPressureControlSystemforResist2anceSpotWelding

SHAOLanjuan,CAOBiao(CollegeofMechanicalandAutomotiveEngineering,SouthChinaUniversityofTechnology,Guangzhou510640,China)

Abstract:Inordertoachievetheprecisecontroloftheresistancespotweldingpressure,thispaperdesignsaspotweldingpressuresystembasedontheservomotorcontrol.Thispaperalsointro2ducesthecontrolsystemgeneralarchitecture,blockdiagramofthehardwareandsoftwarecomponents,andthengivestechnicalpa2rametersofthepressuresystem.Theresultthroughcomparewiththetraditionalmeansofpressureshowsthattheservopressurecontrolsystemforresistancespotweldinghasthefollowingfea2turessuchassmallimpactforceofstubend,fastresponsespeedofpressurechangeandtheprecisecontroltotheelectrodepressure,displacementandspeed,thissystemalsocanmeettherequirementsofpressurechangeinthedifferenttechnology.Keywords:servopressure;controlsystem;electrodepressure;re2

XUXuefeng1,LIUXiaoguang1,ZHAOMin2(1.TheMOEKey

LaboratoryofMechanicalManufactureandAutomation,ZhejiangUniversityofTechnology,Hangzhou310032,China;2.DepartmentofMechanicalEngineering,AnhuiUniversityofTechnologyandScience,Wuhu241000,China)

Abstract:Basingonacomprehensiveoverviewofgeneralfiniteele2mentsimulationmethodofinductionheating,theeffectsofthedif2fusionofmagneticforceattheendofwindingandthedifferenceofmagneticfieldbetweenemptyloadwindingandfullyloadwindingareanalyzed.Theimportanceoftheinductionheatingnumericalsimulationanalysisunderthenon2uniformelectromagneticfieldwiththenovelmethodof22dimensionisproposed.Themovementofbilletinthewirerodisrealizedusingtherepetitiousmodelingmethodandthetransformoftemperaturefielddataindifferentheatingstationiscarriedoutwhencarryingthe22dimensionnu2mericalsimulationofinductionheating.Themethodoftheselec2tionofradiationcoefficientisalsoproposedaccordingtodifferentheatingtemperature.Thesimulationresultsshowthatthetemper2aturecurvesofthebilletin22dimensionmethodareaccordwithpracticebetterthanthatofinone2dimensionmethod.Keywords:inductionheating;finiteelementmethod(FEM);nu2mericalsimulation;temperaturefield;electromagneticfield

StudyonNumericalSimulationTechnologyofBilletInduc2tionHeating

TheTechnologyDiscussofTransmissionMainBoxStruc2tureBonding

SUNZhanchun(StateKeyLaboratoryofTransmissionVehicles,NorthChinaInstituteofVehicles,Beijing100072,China)

Abstract:Thispaperdiscusseswhetherusethestructuraladhesivebondingtomakethetransmissionmainboxintooneunit.Andthispaperalsoexplainsthemaintechnicalproblemsduringtheprocessofadhesiveboding.Itcanreducethedifficultofthecabi2