锻压技术

冷镦挤成形技术在粘贴式锌质平衡块制造中的应用

英文标题：Application of cold upsetting extrusion forming technology in the manufacture of zinc paste type counterbalance

作者：张亚龙徐新成朱建军

单位：上海工程技术大学

分类号：

出版年,卷(期):页码：2016,41(1):66-70

摘要：

研究了锌质粘贴式平衡块冷镦挤成形的可行性，根据零件要求设计了镦挤模具。通过Deform-3D有限元模拟其塑性成形过程，发现在飞边区域损伤因子和表面延伸率较大，零件主体部分成形质量良好；成形载荷峰值低于理论计算值10%左右。按拟定工艺路线生产的零件重量误差在±0.5 g以内；相较于压铸件，零件内部组织更致密、硬度提高了1倍、冲击韧性提高了2倍以上，模具寿命超过15万件，相当于压铸模具寿命的5倍；材料利用率提高了20%左右，避免了压铸过程熔融锌锭工序，显著降低了产品能耗。

It was studied the feasibility of the cold upsetting extrusion forming in the manufacture of zinc paste type counterbalance, and the mould was designed according to the requirements of the part. The simulation of forming process by Deform-3D shows that the damage factor and elongation ratio are more remarkable on the flash edge, however, the quality of the part is good, and the peak of forming load is about 10% lower than that of theoretical calculation. The error of the parts produced according to the proposed process routes is within ±0.5 g in weight. Comparing with die casting products，the internal organization is denser with the hardness increased by one time, and the impact toughness increased by more than two times. Further, the mould life is more than 150000 pieces as five times as that of the mould casting, the material utilization increases by 20% or so. As a result, the molten zinc ingot process is avoided in the die casting process, and the energy consumption of products reduces significantly.

基金项目：

上海市085内涵建设（nhjx-2015-02）

张亚龙（1988-），男，硕士，助理实验师

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