Investigation and production of the grooved part used in the crank pulley using finite element method

Abstract

In recent years, crank pulleys have been manufactured using sheet materials in the automotive industry in line with cost and weight reduction targets. In this production process, sheet materials are first pre-formed and shaped and then a spinning process is applied to obtain the final form with a multi-grooved structure. In this study, 6224 (DD13) 3.5 mm thick sheet material, which is one of the hot rolled steels with low carbon content suitable for cold forming processes, was used. Using Simufact Sheet Metal Forming software, the isotropic Hill-48 material model and the anisotropic kinematic hardening model Chaboche were used to perform detailed analysis on the grooved part in the crank pulleys. The coefficients of the isotropic hardening model were determined from tensile test data and the parameters of Chaboche's kinematic hardening rule were determined from cyclic stress-strain test data. These curves, known as hysteresis cycles, were obtained from low repetition ±3%, ±7% and ±12% fatigue tests. For the determination of the Chaboche model parameters, a strain controlled and symmetrical experiment with one stable cycle was designed and produced. The data obtained from this scope were used as input to the analysis program. Analysis results and prototype manufacturing results were compared.

Keywords

• Pulley
• Spin forming
• Finite element method
• Sheet metal forming
• Kinematic hardening
• Chaboche

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