CN115534353A - Manufacturing process of composite material axle shell assembly for automobile chassis - Google Patents

Abstract

The invention relates to the field of automobiles, in particular to a manufacturing process for a composite axle housing assembly used in an automobile chassis. The axle housing includes a reducer housing, a rear cover housing and a half shaft housing. The reducer housing And the rear cover shell is molded through prepreg molding process, and the half shaft shell is wound through the winding molding process. features.

Description

A manufacturing process of composite axle housing assembly for automobile chassis

technical field

The invention relates to the field of automobiles, in particular to a manufacturing process of a composite axle housing assembly used for an automobile chassis.

Background technique

As one of the important structures of the automobile chassis, the axle is connected to the frame by means of the suspension, and tires are installed on both sides of the axle. Passed to the frame through the suspension. As the main part of the axle, the automobile axle housing is a key component to ensure the normal operation and service life of the automobile, and has requirements for its strength, stiffness and fatigue resistance. If the casing breaks during the running of the vehicle, the load-carrying capacity of the vehicle body will be reduced, thereby causing safety accidents. Therefore, the axle housing has a very critical influence on the driving safety and the comfort of the vehicle. At present, most of the axle housings used in automobiles are made of cast steel, which is of high quality and will have an impact on fuel efficiency and endurance.

Therefore, the inventor does further research on this, develops a kind of composite material axle housing assembly manufacturing process that is used for automobile chassis, and this case results from this.

Contents of the invention

The purpose of the present invention is to provide a composite material axle housing assembly manufacturing process for automobile chassis. characteristics of rust.

In order to achieve the above object, the technical scheme of the present invention is as follows:

A manufacturing process for a composite axle housing assembly used in an automobile chassis. The axle housing includes a reducer housing, a rear cover housing and a half shaft housing. The reducer housing and the rear cover housing are prepreg Material compression molding process, half-shaft shell through winding molding process, the specific preparation method steps are as follows:

The molding process of the reducer housing and the rear cover housing includes:

Step A1, analyze the load of the shell, and carry out the lay-up design: calculate the distribution of the maximum bending load when the shell is bent according to the loading conditions of the reducer shell and the rear cover shell during work , select materials and lay-up design to ensure the required strength and stiffness;

Step A2, the design of the mould: prepare the mold corresponding to the shape of the inner cavity and the reducer housing and the back cover housing, the part corresponding to the reducer housing in the mold cavity is the reducer housing cavity, and the part corresponding to the back cover housing The corresponding part is the housing cavity of the back cover. Use a white clean cotton cloth to dip the release agent, wipe the mold cavity completely, and preheat the mold to 40°C-60°C;

Step A3, preparation of prepreg: cut the spare carbon fiber and basalt fiber fabric according to the shape of the reducer housing and the rear cover housing, then mix the above fiber fabric with resin to obtain prepreg, and preheat at 40°C ;

Step A4, molding of the shell: Lay the preheated prepreg in the mold according to the designed plan, the prepreg is impregnated, flows and fills the mold cavity under pressure, and finally it is cooled under pressure and demoulded complete molding;

Step A5, post-molding treatment: trimming and punching the product after demoulding to obtain the final product;

The preparation steps of the half shaft shell are as follows:

Step B1, shell load analysis and lay-up design: calculate the distribution of the maximum torsional force that the half-shaft bears when torsioned according to the loaded situation of the half-shaft shell, select fiber materials and carry out lay-up design;

Step B2, mandrel manufacturing and winding machine: prepare the steel mandrel of required size, and adjust the winding machine system;

Step B3, the preparation of prepreg tape: reinforcing fiber is placed in the resin tank of winding machine, then inject resin and fully mix with fiber;

Step B4, winding of the prepreg tape: the mandrel rotates at a predetermined speed under the control of the drive control system, and the resin tank travels back and forth at a set speed, so that the prepreg tape is arranged on the mandrel in a spiral;

Step B5, the curing of prepreg tape: the prepreg tape wound on the mandrel is put into the incubator, set temperature and time to cure;

Step B6, post-curing treatment.

Further, in step A2, the mold adopts a rounded corner design; in step A3, epoxy resin is selected as the resin.

Further, in step A2, increase the design of the connection between the reducer housing and the half shaft, and adopt the method of spline connection and adhesive connection. Choose 3M DP460 structural adhesive.

Further, in step A4, the prepreg is immediately laid in the preheated mold after preheating.

Further, in step A2, in the reducer housing, the metal spline and the composite material housing are connected to the housing by means of adhesive connection and hinged connection, and the composite material reinforcing rib and the metal spline are connected by adhesive , Adhesive selection 3M DP460 structural adhesive.

Further, in step A4, 30 layers are laid on the inner surface of the reducer housing at a lay-up angle of 0°, 50 layers of reinforcing ribs are laid at a lay-up angle of 45°, and 40 layers are laid at a cylindrical interface at a lay-up angle of ±45°. Lay 40 layers on the remaining outer surface according to the laying angle of 0°/45°/-45°/0°, and lay 30 layers on the rear cover shell according to the laying sequence of 0°/45°/-45°. In order to reduce the stress concentration at the opening of the rear cover shell, 10 layers of prepreg with a layup angle of ±45° are added to the opening to ensure the reliability of the opening.

Further, in step B1, 30 layers are laid using a 45°/-45° layup.

Further, in step B2, the connection at the end of the mandrel adopts an external spline connection and an adhesive connection, the external spline has 8 key grooves, and the adhesive is 3M DP460 structural adhesive

Further, in step B3, during the preparation of the prepreg, the temperature is controlled so that the residual solvent is removed, and the prepreg tape cannot be solidified and bubbles can not be generated simultaneously.

Further, in step A4, after curing, the metal internal spline is connected to the inner and outer surfaces of the housing through adhesive and hinged joints, the cylindrical interface is connected to the housing by adhesive, and the reinforcing rib is connected to the spline by adhesive Connected to the outer surface of the shell.

Further, in step B5, the metal external spline is connected with the prepreg tape wound on the mandrel by means of an adhesive, and then put into a constant temperature box for curing.

After adopting the above scheme, the present invention has the following advantages compared with the prior art:

The composite axle housing assembly is an axle housing made of fiber-reinforced resin-based composite materials. Under the premise of the same rigidity, the weight of the composite axle housing assembly is lighter than that of the metal axle housing assembly. In addition, due to the superior characteristics of composite materials such as high specific strength and specific modulus, no rust, good fatigue resistance, and good damping and shock absorption performance, the bearing capacity and energy storage capacity of the composite axle housing It is also better than the metal axle housing; the overall performance of the composite axle housing is obviously better than that of the metal axle housing, and has a good application prospect.

Description of drawings

Fig. 1 is a schematic diagram of the structure of the axle housing assembly of the present invention;

Figure 2 is a schematic diagram of the structure of the reducer housing;

Fig. 3 is a schematic diagram of the structure of the half shaft housing;

Fig. 4 is a schematic diagram of the structure of the rear cover shell;

Fig. 5 is a flow chart of the molding process;

Fig. 6 is a winding forming process flow chart;

Figure 7 is a schematic cross-sectional view of the half shaft housing;

Label description

Half shaft housing 1, reducer housing 2, rear cover housing 3, reinforcement rib 4, inner spline 5, outer spline 6, plain cloth 7.

detailed description

The present invention will be further described below in conjunction with the accompanying drawings and specific embodiments.

As shown in Figure 1, a composite axle housing is composed of a reducer housing, a half shaft housing, and a rear cover housing. The composite material is made of thermoplastic resin as a matrix, and basalt, carbon fiber or glass fiber is a reinforcing fiber. composition.

During the molding process, in order to ensure that the performance of the composite material is not affected, the mold and prepreg should be preheated in advance, and the laying should be done as soon as possible to reduce the contact time with air.

As shown in Figures 2 and 4, in order to avoid damaging the fibers during laying, affecting the quality of the prepreg and ultimately affecting the performance of the final molded product, rounded corners are used on the straight edges.

As shown in Figures 2 and 3, in order to ensure the reliability of the connection of the shell, a spline connection is adopted at the connection between the half shaft and the reducer. The inner and outer splines each have 8 key grooves to increase the contact area and improve the bearing capacity. At the same time, three reinforcing ribs are added to increase the rigidity and strength of the shell, and in order to strengthen the connection effect, 3M DP460 structural adhesive is used for bonding at the same time. The adhesive will expand when it is cured, which can make the connection effect better and The adhesive has a large fracture strain, and can bear a high fatigue limit stress, thereby increasing the fatigue life and improving the reliability of the connection.

In the molding process, in order to ensure the quality of the mold and the final product, it is necessary to use a white clean cotton cloth to dip the mold release agent, and wipe the cavity of the molding mold completely, so that it is carried out 3 to 5 times, and the interval between each time is 15 to 20. Minutes, the last storage time is greater than 30 minutes.

As shown in Figure 7, in order to make the half-shaft shell 1 have the best anti-torsion performance, the reinforced fiber winding in the composite material adopts the -45°/45° winding method, that is, the reinforcing fibers in the warp and weft directions are cross-wound to form a plain weave Cloth 7, this plain weave can not only ensure the strength of the half shaft shell 1, but also enhance the fatigue life and impact resistance of the shell 1.

According to the mechanics of materials, under the condition of torsional deformation, when the reinforcing fiber arrangement direction forms an acute angle with the axial direction, the acute angle ranges from 30° to 60°, especially when the acute angle is 45°, the reinforcing fiber can be fully exerted. High strength and high modulus, so the warp and weft reinforcement fibers of the plain weave 6 are at 45° to the shaft.

The composite material reducer housing 2 and the rear cover housing 3 are prepared by the following process:

1. Load distribution analysis of the shell and lay-up design

①Load analysis

According to the load of the shell during work, the distribution of the bending load force when the shell is subjected to the maximum load when it is bent is calculated in the finite element ABAQUS, and the basalt and carbon fiber are selected to have high strength, high modulus, high fatigue resistance and Fiber material with low temperature resistance.

②Layer design

According to the finite element analysis results, 30 layers are laid on the inner surface of the reducer shell at a laying angle of 0°, 50 layers of reinforcing ribs are laid at a laying angle of ±45°, and 40 layers are laid at a cylindrical interface at a laying angle of ±45°. Lay 40 layers on the remaining outer surface of the shell according to the laying angle of 0°/45°/-45°/0°, and lay 30 layers on the back cover shell according to the laying sequence of 0°/45°/-45°, and lay Lay 10 layers of reinforced layers at the hole according to the laying angle of ±45°, which can achieve the required strength;

2. Mold design and prepreg preparation

①Prepreg preparation

Cut the spare carbon fiber and basalt fiber fabrics according to the shapes of the reducer housing 2 and the rear cover housing 3. The selected fabrics are all orthogonal fiber fabrics or unidirectional fiber fabrics. After mixing the matrix resin and curing agent at 100:33, After the fibers are modified, they are mixed with the resin matrix in the form of silk, yarn, cloth, felt, etc. to make prepregs and preheated at 40°C in advance.

②Mold design and pretreatment

Prepare a mold with an inner cavity shape corresponding to the reducer and the rear cover, the part corresponding to the reducer housing 2 in the mold cavity is the reducer housing cavity, and the part corresponding to the rear cover housing 3 is the rear cover housing cavity. To ensure the quality of the mold and shell, use a clean white cotton cloth to dip the mold release agent, wipe the mold cavity completely, and preheat the mold to 40°C-60°C.

3. Curing of the shell and post-curing treatment

① Laying of prepreg

The preheated prepreg is laid in the mold cavity to form a fiber layup. The weight of the carbon fiber fabric laid in the reducer housing cavity and the rear cover housing cavity is 40% of the weight of the fiber layup. The basalt fiber fabric and carbon fiber fabric used Orthogonal fabrics or unidirectional fabrics of ±45° and 0°/90° are laid in the corresponding molds, and the adhesion between the prepreg and the mold is ensured.

The fiber layer in the mold cavity of the rear cover shell is composed of a mixed base layer, a transition layer and a reinforcement layer that are sequentially stacked from top to bottom. The mixed base layer is formed by laying basalt prepreg and carbon fiber prepreg. The transition layer is composed of Basalt prepreg is laid, and the reinforcement layer is formed by laying carbon fiber prepreg. At the same time, in order to reduce the composite material fiber fracture and stress concentration at the opening, a reinforcement layer is set at the opening.

The base layer is formed by laying orthogonal basalt and carbon fiber prepreg alternately from top to bottom at a 0° layup angle, wherein 5 layers of basalt and carbon fiber are each laid. The transition layer is laid with 10 layers of basalt unidirectional cloth prepreg at a layup angle of 45°. The reinforcement layer is laid with 10 layers of carbon fiber orthogonal cloth prepreg at a ply angle of -45°. The reinforcement layer has 10 layers of carbon fiber orthogonal prepreg laid at a layup angle of ±45°.

The structure of the reducer shell is relatively complicated. When laying the prepreg, it is selected to lay the inside and outside separately. The outer surface of the reducer shell cavity is divided into reinforcement ribs, cylindrical interfaces and the laying of the rest of the outer surface. The rest of the outer surfaces are laid in sequence from top to bottom. The mixed base layer, the transition layer, the reinforcement layer and the top layer, the hybrid base layer is formed by laying basalt prepreg and carbon fiber prepreg, the transition layer is formed by laying basalt prepreg, and the reinforcement layer is formed by carbon fiber Prepreg is laid up, and the top layer is formed by laying up basalt and carbon fiber prepreg. The inner surface of the reducer housing is formed by laying basalt and carbon fiber.

The mixed base layer is formed by alternate laying of orthogonal basalt and carbon fiber prepreg from top to bottom at a layup angle of 0°, in which 5 layers of basalt and carbon fiber are respectively laid, and the transition layer is made of basalt unidirectional cloth prepreg with 45 ° Lay 10 layers at the ply angle. The reinforcement layer is laid with 10 layers of carbon fiber unidirectional prepreg at a ply angle of -45°. The top layer of orthogonal basalt and carbon fiber prepregs are laid alternately from top to bottom at a layup angle of 0°, wherein 5 layers of basalt and carbon fiber are laid respectively.

The reinforcement is formed by laying 50 layers of orthogonal carbon fiber prepreg from top to bottom at a 45° layup angle.

The cylindrical interface is formed by laying 40 layers of orthogonal carbon fiber prepreg from top to bottom at a layup angle of ±45°.

The inner surface of the reducer housing cavity is formed by laying orthogonal basalt and carbon fiber prepreg alternately from top to bottom at a 0° layup angle, of which 15 layers of basalt and carbon fiber are each laid.

② Shell curing

After the prepreg laying is completed, the male mold and the female mold are quickly closed. After the mold is closed, the hot press is used for continuous curing for 120 minutes at a temperature of 120°C and a pressure of 400Pa.

③Remoulding and curing

After the composite material shell is cured and molded, the basic cured product is obtained, and then it is placed in a constant temperature box and cured at a temperature of 120°C for 120 minutes.

④ Shell connection and curing

After the inner surface of the reducer, the reinforcing rib, the cylindrical interface and the rest of the outer surface are demoulded and solidified, the metal inner spline is connected to the inner and outer surfaces of the housing through adhesive and hinged joints, and the reinforcing rib and cylindrical interface are connected by adhesive It is connected with the spline and the outer surface of the shell, and the adhesive is selected from 3M DP460 structural adhesive, and then placed in a constant temperature box, and cured at a temperature of 120°C for 120 minutes.

⑤ shell grinding

After the curing process is completed, it is deburred and polished.

Composite material half-shaft housing 4 is prepared through the following preparation process:

1. Load distribution analysis of the shell and lay-up design

①Load analysis

According to the loading of the shell during work, the distribution of the torsional load force when the shell is torsionally subjected to the maximum load is calculated in the finite element ABAQUS, and the glass fiber and carbon fiber are selected to have high strength, high modulus, and high fatigue resistance. And fiber materials with low temperature resistance.

②Layer design

According to the finite element analysis results, the required strength can be achieved when the composite material shell is laid with 20 layers according to the layup of ±45°.

2. Mandrel preparation and winding machine debugging

Prepare the corresponding mandrel according to the shape and size of the designed half-shaft shell, and adjust the speed and angle required by the winding machine at the same time.

3. Curing of prepreg tape

① Winding of prepreg tape

Put the reinforcing fiber into the resin tank of the winding machine, then inject the resin for mixing, and then the winding machine will wind the prepreg tape on the mandrel at a speed of 10m/min and an appropriate tension.

After the winding fiber is put into the resin tank, it is necessary to add acetone diluent to mix with the resin to avoid air bubbles during winding and affect the product. For the winding fiber layer, glass fiber and carbon fiber are selected to be cross-wound at ±45°, and the number of winding layers is 20 layers. During the winding process, drying is carried out at the same time to drive off the solvent in the fiber tape, which can greatly reduce the air bubbles and voids in the product.

② curing

Connect the metal external spline with the prepreg tape wound on the mandrel by means of adhesive, then put it into a constant temperature box, and set 120°C to cure for 360 minutes.

4. Post-curing treatment

Deburring and grinding are performed on the cured housing.

So far, the preparation of the composite axle housing assembly is completed.

Through several tests to test the relationship between materials, laying methods and curing temperature, see the table below:

Above-mentioned is only the specific embodiment of the present invention, all the words such as " up, down, left, right, middle " involved in the present invention are only used for reference, are not absolutely limited, all utilize the present invention to carry out non-essential Any change should be an act of violating the protection scope of the present invention.

Claims (10)

1. A manufacturing process for a composite axle housing assembly of an automobile chassis, the axle housing includes a speed reducer housing, a rear cover housing and a half shaft housing, and it is characterized in that the speed reducer housing and the rear axle housing The cover shell is formed by prepreg molding process, and the half-shaft shell is formed by winding process. The specific preparation method steps are as follows: The molding process of the reducer housing and the rear cover housing includes: Step A1, analyze the load of the shell, and carry out the layup design: calculate the distribution of the maximum bending load force of the shell when it is bent according to the load conditions of the reducer shell and the rear cover shell during work, Selection of materials and layup design to ensure the required strength and stiffness; Step A2, the design of the mould: prepare the mold corresponding to the shape of the inner cavity and the reducer housing and the back cover housing, and the part corresponding to the reducer housing in the mold cavity is the reducer housing cavity, which is corresponding to the back cover housing. The corresponding part is the housing cavity of the back cover. Use a white clean cotton cloth to dip the release agent, wipe the mold cavity completely, and preheat the mold to 40°C-60°C at the same time; Step A3, preparation of prepreg: cut the spare carbon fiber and basalt fiber fabric according to the shape of the reducer housing and the rear cover housing, then mix the above fiber fabric with resin to obtain prepreg, and preheat at 40°C ; Step A4, molding of the shell: Lay the preheated prepreg in the mold according to the designed plan, the prepreg is impregnated, flows and fills the mold cavity under pressure, and finally it is cooled under pressure and demoulded complete molding; Step A5, post-molding treatment: trimming and punching the product after demoulding to obtain the final product; The preparation steps of the half shaft shell are as follows: Step B1, analyze the shell load and carry out lay-up design: calculate the distribution of the maximum torsional force that the half-shaft bears when torsioned according to the loaded condition of the half-shaft shell, select fiber materials and carry out lay-up design; Step B2, mandrel manufacturing and winding machine: prepare a steel mandrel of required shape and size, and adjust the winding machine system; Step B3, preparation of prepreg tape: place reinforcing fiber in the resin tank of winding machine, then inject resin and fully mix with fiber; Step B4, winding of the prepreg tape: the mandrel rotates at a predetermined speed under the control of the drive control system, and the resin tank travels back and forth at a set speed, so that the prepreg tape is arranged on the mandrel in a spiral; Step B5, curing of prepreg tape: put the prepreg tape wound on the mandrel into an oven, set temperature and time to cure; Step B6, post-curing treatment. 2. A manufacturing process for a composite axle housing assembly for an automobile chassis according to claim 1, characterized in that: in step A2, the mold adopts a rounded corner design; in step A3, the resin is selected from epoxy resin . 3. A manufacturing process for a composite axle housing assembly for an automobile chassis according to claim 1, characterized in that: in step A2, increase the design of the connection between the reducer housing and the axle shaft, using The method of spline connection plus adhesive connection, the internal spline has a total of 8 key grooves, and three reinforcement ribs are provided at the same time, and the adhesive is 3M DP460 structural adhesive. 4. A manufacturing process for a composite axle housing assembly for an automobile chassis according to claim 1, characterized in that: in step A4, the prepreg is preheated and immediately laid on the preheated mold middle. 5. A manufacturing process for a composite axle housing assembly for an automobile chassis according to claim 1, characterized in that: in step A4, 30 layers are laid in the reducer housing according to a lay-up angle of 0°. Interfaces, outer surface reinforcement ribs and other outer surfaces are respectively laid with 40 layers according to the laying angles of ±45°, ±45° and 0°/45°/-45°/0°, and the back cover shell is laid according to 0°/45° Lay 30 layers in the ply sequence of /-45°, and lay 10 layers at ±45° at the opening. 6. A manufacturing process for a composite axle housing assembly for an automobile chassis according to claim 1, characterized in that: in step B1, 30 layers are laid with 45°/-45° layers. 7. A manufacturing process for a composite axle housing assembly for an automobile chassis according to claim 1, characterized in that: in step B2, the joints at the ends of the mandrel are connected by external splines and glued There are 8 key slots in the external spline, and the adhesive is 3M DP460 structural adhesive. 8. A manufacturing process for a composite axle housing assembly for automobile chassis according to claim 1, characterized in that: in step B3, during the preparation of the prepreg, the temperature is controlled to remove the residual solvent, and at the same time, the Allow prepreg tape to cure and generate bubbles. 9. A manufacturing process for a composite axle housing assembly for an automobile chassis according to claim 1, characterized in that: in step A4, after solidification, the metal inner splines are connected to the inner splines through an adhesive and a hinged joint. The key is connected with the inner and outer surfaces of the housing, the cylindrical interface is connected with the housing by adhesive, and the reinforcing rib is connected with the spline and the outer surface of the housing by adhesive. 10. A manufacturing process for a composite axle housing assembly for an automobile chassis according to claim 1, characterized in that: in step B5, the metal external spline and the prepreg tape wound on the mandrel are It is connected by adhesive, and then placed in a constant temperature box for curing.

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