锻压技术

汽车法兰轴结构件塑性成形工艺分析及改进

英文标题：Analysis and improvement on plastic forming process for structure

作者：姚文俊陈松

分类号：TG376.3

出版年,卷(期):页码：2020,45(11):7-12

摘要：

针对某汽车法兰轴结构件的几何特征，结合塑性成形理论，初步提出了两种法兰轴冷镦挤成形工艺方案。采用有限元软件DEFORM-3D，对两种工艺方案的成形过程进行了数值仿真，分析并比较了两种工艺方案的材料流动情况、材料损伤值及成形载荷。结果表明：工艺方案1中的材料损伤值、成形载荷均大于工艺方案2，且法兰轴存在材料折叠的缺陷，因此，采用工艺方案2成形结构件。基于工艺方案2，以成形过程中模具承受载荷最小为目标，建立了关于预成形锥角、终成形下模圆角半径、摩擦系数及冷镦速度的正交试验，分析了各试验参数的关键程度，最终获得了工艺方案2的最佳工艺参数。最后，分别进行了两种工艺方案的零件试制，工艺方案1的工件存在材料折叠的现象，工艺方案2的工件成形良好，验证了有限元仿真的正确性。

According to the geometric characteristics of an automobile flange shaft structure part, combined with the plastic forming theory, two kinds of cold upsetting extrusion forming process schemes for flange shaft were preliminarily proposed. Then, the forming processes of the two process schemes were simulated by the finite element software DEFORM-3D, and the material flow, the material damage value and the forming load of the two process schemes were analyzed and compared. The results show that the material damage value and the forming load in process scheme 1 are greater than those in process scheme 2, and the flange shaft has the defect of material folding, so the process scheme 2 is adopted. Based on the process scheme 2, aiming at the minimum load of die during the forming process, the orthogonal test with pre-forming cone angle,fillet radius of final forming lower die, friction coefficient and cold upsetting speed was established, the key degree of each test parameter was analyzed, and the optimal process parameters of process scheme 2 were finally obtained. In the end, the parts of two process schemes were trial manufactured respectively. And there is material folding in process scheme 1, but the workpiece is well formed by process scheme 2, which verifies the correctness of finite element simulation.

基金项目：

南通航运职业技术学院院级重点招标项目（HYJY/2018A04）；江苏省面上项目（17KJB460010）

姚文俊（1971-），男，工程硕士，副教授 E-mail：1366226431@qq.com

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