基于正交试验管廊固定螺母冷镦成形的分析及优化
|
摘要
以某市政管廊固定螺母冷镦成形为例,基于Archard磨损理论,采用有限元分析软件Deform-3D对螺母冷镦过程中工位4下冲头进行优选。然后通过正交试验得到冲压速度、模具表面硬度、模芯圆角半径、摩擦系数对下冲头磨损的影响规律,得到最优工艺参数组合为:冲压速度5 mm·s~(-1)、模具表面硬度58 HRC、模芯圆角半径3 mm、摩擦系数0.13。采用优化后参数进行模拟分析,下冲头最大磨损量为2.93×10~(-5)mm,较优化前大幅降低,基于模拟结果预测出下冲头使用寿命。最后采用最优参数组合进行试模,工件质量良好,未出现材料折叠、拉毛等缺陷,符合生产要求,为制件实际生产提供了理论依据。
Taking the cold heading formed fixing nut of a municipal pipe gallery as an example,the lower punch of station four during cold heading process of nut was optimized by finite element software Deform-3 D based on Archard wear theory. Then,the influences of stamping speed,hardness of mold surface,fillet radius of mould core and friction coefficient on the wear of lower punch were obtained by orthogonal test. The obtained optimum parameters were the punching speed of 5 mm · s~(-1),the hardness of mould surface surface of 58 HRC,the fillet radius of mould core of 3 mm and the friction coefficient of 0. 13. Through the simulation analysis with optimal parameters,the maximum wear of lower punch was 2. 93 × 10~(-5) mm,which was reduced significantly compared with that before optimization,and then the service life of lower punch was predicted based on simulation results. Moreover,a mould test was carried out with the optimal parameters. And the workpiece has a good quality without material defects such as folding and nap,which meets the production requirements and provides a theoretical basis for actual production.
Taking the cold heading formed fixing nut of a municipal pipe gallery as an example,the lower punch of station four during cold heading process of nut was optimized by finite element software Deform-3 D based on Archard wear theory. Then,the influences of stamping speed,hardness of mold surface,fillet radius of mould core and friction coefficient on the wear of lower punch were obtained by orthogonal test. The obtained optimum parameters were the punching speed of 5 mm · s~(-1),the hardness of mould surface surface of 58 HRC,the fillet radius of mould core of 3 mm and the friction coefficient of 0. 13. Through the simulation analysis with optimal parameters,the maximum wear of lower punch was 2. 93 × 10~(-5) mm,which was reduced significantly compared with that before optimization,and then the service life of lower punch was predicted based on simulation results. Moreover,a mould test was carried out with the optimal parameters. And the workpiece has a good quality without material defects such as folding and nap,which meets the production requirements and provides a theoretical basis for actual production.
引文
[1]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.
[2]孙英达,徐文琴.大模数矩形花键冷挤压成形质量分析[J].兵器材料科学与工程,2015,38(4):73-75.Sun Y D,Xu W Q.Quality analysis on cold extrusion forming of big modulus rectangle spline[J].Ordnance Material Science and Engineering,2015,38(4):73-75.
[3]肖志玲,李世瑜,刘华,等.小型薄壁套管多工位冷镦挤工艺[J].锻压技术,2017,42(3):15-19.Xiao Z L,Li S Y,Liu H,et al.Multi-stage cold forging and extruding process of small thin wall casing[J].Forging&Stamping Technology,2017,42(3):15-19.
[4]Kim D H,Lee H C,Kim B M,et al.Estimation of die service life against plastic deformation and wear during hot forging processes[J].Journal of Materials Processing Technology,2005,166(3):372-380.
[5]史双喜,李福涛.基于Deform的精冲模具磨损特性研究[J].润滑与密封,2015,40(7):89-92.Shi S X,Li F T.Research on fine blanking die wear based on Deform[J].Lubrication Engineering,2015,40(7):89-92.
[6]毛华杰,蒋厚生,刘艳雄,等.斜齿圆柱齿轮旋转精冲过程模具磨损模拟分析[J].锻压技术,2016,41(3):88-93.Mao H J,Jiang H S,Liu Y X,et al.Simulation analysis on die wear in rotational fine blanking for helical gears[J].Forging&Stamping Technology,2016,41(3):88-93.
[7]张东民,刘铭心,盛育东,等.汽车座椅外侧板单动拉延成形工艺分析及优化[J].锻压技术,2017,42(6):61-65.Zhang D M,Liu M X,Sheng Y D,et al.Process analysis and optimization on single drawing for outer panel of automobile seat[J].Forging&Stamping Technology,2017,42(6):61-65.
[8]陈吉清,王玉超,兰凤崇.基于正交试验的汽车覆盖件冲压工艺参数优化[J].计算机集成制造系统,2007,13(12):2433-2440.Chen J Q,Wang Y C,Lan F C.Optimization for stamping process parameters of automotive body parts based on orthogonal experiments[J].Computer Integrated Manufacturing Systems,2007,13(12):2433-2440.
[9]孙宪萍,刘强强,杨兵,等.基于磨损正交试验的温挤压模具优化设计[J].润滑与密封,2016,41(6):73-76.Sun X P,Liu Q Q,Yang B,et al.Optimization design on warm extrusion die based on orthogonal experiments of wear[J].Lubrication Engineering,2016,41(6):73-76.
[2]孙英达,徐文琴.大模数矩形花键冷挤压成形质量分析[J].兵器材料科学与工程,2015,38(4):73-75.Sun Y D,Xu W Q.Quality analysis on cold extrusion forming of big modulus rectangle spline[J].Ordnance Material Science and Engineering,2015,38(4):73-75.
[3]肖志玲,李世瑜,刘华,等.小型薄壁套管多工位冷镦挤工艺[J].锻压技术,2017,42(3):15-19.Xiao Z L,Li S Y,Liu H,et al.Multi-stage cold forging and extruding process of small thin wall casing[J].Forging&Stamping Technology,2017,42(3):15-19.
[4]Kim D H,Lee H C,Kim B M,et al.Estimation of die service life against plastic deformation and wear during hot forging processes[J].Journal of Materials Processing Technology,2005,166(3):372-380.
[5]史双喜,李福涛.基于Deform的精冲模具磨损特性研究[J].润滑与密封,2015,40(7):89-92.Shi S X,Li F T.Research on fine blanking die wear based on Deform[J].Lubrication Engineering,2015,40(7):89-92.
[6]毛华杰,蒋厚生,刘艳雄,等.斜齿圆柱齿轮旋转精冲过程模具磨损模拟分析[J].锻压技术,2016,41(3):88-93.Mao H J,Jiang H S,Liu Y X,et al.Simulation analysis on die wear in rotational fine blanking for helical gears[J].Forging&Stamping Technology,2016,41(3):88-93.
[7]张东民,刘铭心,盛育东,等.汽车座椅外侧板单动拉延成形工艺分析及优化[J].锻压技术,2017,42(6):61-65.Zhang D M,Liu M X,Sheng Y D,et al.Process analysis and optimization on single drawing for outer panel of automobile seat[J].Forging&Stamping Technology,2017,42(6):61-65.
[8]陈吉清,王玉超,兰凤崇.基于正交试验的汽车覆盖件冲压工艺参数优化[J].计算机集成制造系统,2007,13(12):2433-2440.Chen J Q,Wang Y C,Lan F C.Optimization for stamping process parameters of automotive body parts based on orthogonal experiments[J].Computer Integrated Manufacturing Systems,2007,13(12):2433-2440.
[9]孙宪萍,刘强强,杨兵,等.基于磨损正交试验的温挤压模具优化设计[J].润滑与密封,2016,41(6):73-76.Sun X P,Liu Q Q,Yang B,et al.Optimization design on warm extrusion die based on orthogonal experiments of wear[J].Lubrication Engineering,2016,41(6):73-76.