Spinning Process Design and Numerical Simulation of Pulley

Taking the automotive electromagnetic clutch pulley as the research object, the step-by-step spinning forming process of the pulley thermal pre-forming and final forming at room temperature was designed. A simplified finite element simulation model of the pulley was created with UG three-dimensional software, and the step-by-step spinning process of the pulley was simulated with DEFORM-3D finite element analysis software to explore the metal flow and stress state of the pulley in the spinning deformation process. The results show that with the feed of the pre-rotating wheel, the spinning blank metal flows upwards along the side wall of the rotating wheel. When the feed of the pre-rotating wheel is 0.8 mm, the side wall of the annular flat groove is close to the target size, and the final wheel feed is 0.6 mm, and the tooth profile of the belt wheel is filled.At the beginning of spinning, the maximum equivalent stress of the blank increases with the feed of the spinning wheel, and the stress tends to stable after the blank is gradually formed. Compared with the pre-spinning process, the equivalent stress increment of final spinning at room temperature is larger. The simulation results of the pulley spinning meet the shape and size requirements of the parts, and the main process parameters such as the rotation speed and the feed rate of the rotation wheel are reasonable, and the spinning process designed is suitable for the near-net forming process of electromagnetic pulleys.