小型薄壁套管多工位冷镦挤工艺
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摘要
小型薄壁套管类零件,整体尺寸较小且内外结构复杂,加工方法的选择和成形工艺设计方面是生产该类零件的重点和难点。针对上述难点,采用适合中小型零件批量加工的多工位冷成形加工方法,并根据成形理论分析,初步设计出两种较合理的六工位冷成形方案,对成形过程采用Deform-3D软件数值模拟。得出先反挤压成形薄壁端的最大载荷为5.6×104N,远小于先镦粗成形凸缘的最大载荷;台阶深孔的成形采用杯-杯复合挤压,其损伤值远小于材料的临界损伤值。最终通过生产试验验证模拟结果的最佳工艺,且成形后小型薄壁套管的内部组织分布合理,无冷镦缺陷。
For small thin wall casing parts with a small size but a complex structure,the choice of processing methods and forming process design are main difficulies.In view of the above difficulties,the multi-stage cold forming method suitable for small and medium-sized parts batch processing was proposed,and two more reasonable six-stage cold forging processes was designed based on the forming theory analysis.Then,the forming process was simulated by Deform-3D software,and the maximum load of the thin-walled end 5.6 × 104 N produced by the first anti-extrusion was far less than that produced by first upsetting flange.Furthermore,the deep hole with step was formed by the cup-cup compound extrusion,and the damage value of material was much smaller than that of the critical damage.Finally,the optimal program of simulation results are verified by the production test,and the microstructural distribution is reasonable without cold upsetting defects.
For small thin wall casing parts with a small size but a complex structure,the choice of processing methods and forming process design are main difficulies.In view of the above difficulties,the multi-stage cold forming method suitable for small and medium-sized parts batch processing was proposed,and two more reasonable six-stage cold forging processes was designed based on the forming theory analysis.Then,the forming process was simulated by Deform-3D software,and the maximum load of the thin-walled end 5.6 × 104 N produced by the first anti-extrusion was far less than that produced by first upsetting flange.Furthermore,the deep hole with step was formed by the cup-cup compound extrusion,and the damage value of material was much smaller than that of the critical damage.Finally,the optimal program of simulation results are verified by the production test,and the microstructural distribution is reasonable without cold upsetting defects.
引文
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[2]Sun M C,Tzou G Y,Zheng L A.Processing animation simulation and FEM analysis of multi-stage cold forging of stainless automotive battery fastener[J].Indian Journal of Engineering&Materials Sciences,2013,20(3):219-224.
[3]张东民,盛育东,吴艳云,等.偏心螺母的多工位冷镦成形工艺数值模拟及优化[J].锻压技术,2016,41(11):21-27.Zhang D M,Sheng Y D,Wu Y Y,et al.Numerical simulation and optimization on multi-station cold heading of eccentric nut[J].Forging&Stamping Technology,2016,41(11):21-27.
[4]Lenik K,Korga S.Deform 3D and solidworks FEM tests in conditions of sliding friction[J].Materials Science and Engineering,2012,56(2):89-92.
[5]熊盛勇,夏琴香,陈亚兵,等.基于数值模拟的空调换热器翅片多道次级进拉深成形过程研究[J].锻压技术,2015,40(1):27-32.Xiong S Y,Xia Q X,Chen Y B,et al.Research on multi-step progressive drawing of conditioner heat exchanger fin based on numerical simulation[J].Forging&Stamping Technology,2015,40(1):27-32.
[6]Cao T S,Vachey C,Montmitonnet P,et al.Comparison of reduction ability between multi-stage cold drawing and rolling of stainless steel wire experimental and numerical investigations of damage[J].Journal of Materials Processing Technology,2015,217:30-47.
[7]Yoon J,Jeon H,Lee J.Process design of cold forging with thick plate for seat recliner parts[J].Materials&Design,2013,49:449-455.
[8]王贤鹏,王雷刚,申剑,等.薄壁深筒形件活塞温冷复合挤压成形工艺研究[J].热加工工艺,2016,45(5):104-107.Wang X P,Wang L G,Shen J,et al.Study on warm and cold combined extrusion forming process of thin-walled deep cylindrical pieces of piston[J].Hot Working Technology,2016,45(5):104-107.
[9]赵晨阳,李洪波,韩金成,等.花键轮精密锻造成形的数值模拟及实验研究[J].锻压技术,2016,41(1):11-15.Zhao C Y,Li H B,Han J C,et al.Numerical simulation and experimental research on precision forging for spline gear[J].Forging&Stamping Technology,2016,41(1):11-15.
[10]Huo Y M,Wang B Y,Bai Q,et al.Viscoplastic damage constitutive modelling of high speed railway axle steel 25Cr Mo4[J].Key Engineering Materials,2014,622:679-686.
[11]Tzou G Y,Sun M C,Zheng L A.The die stress and forging streamline analysis of stainless automotive battery fastener[J].Materials Research Innovation,2014,18(S3):31-37.
[12]Singh P C.Investigation of dynamic effects during cold upset-forging of sintered aluminium truncated conical preforms[J].Journal of Materials Processing Technology,2011,211(7):1285-1295.
[13]肖志玲,刘百宣,刘华,等.销钉多工位冷镦成形过程数值模拟及组织演变[J].热加工工艺,2014,43(17):119-124.Xiao Z L,Liu B X,Liu H,et al.Numerical simulation and microstructure evolution on multi-station cold heading of pin[J].Hot Working Technology,2014,43(17):119-124.
[14]胡福生,王宝雨,胡正寰.楔横轧凸轮轴金属流动规律的有限元分析[J].北京科技大学学报,2010,32(6):797-801.Hu F S,Wang B Y,Hu Z H.FEM analysis on the metal flow rule of cross wedge rolling cam shafts[J].Journal of University of Science and Technology Beijing,2010,32(6):797-801.