锻压技术

基于数值模拟的钢珠套螺杆多工位冷锻工艺优化

英文标题：Optimization on multi-station cold forging process of steel ball sleeve screw based on numerical simulation

单位：河南科技大学

分类号：TG316

出版年,卷(期):页码：2020,45(9):22-28

摘要：

针对汽车零部件钢珠套螺杆的成形设计了两套工艺方案。第1套方案的工序2在大高径比镦粗成形时，零件易出现鼓形部位侧面不平整以及折叠的问题，其中，高径比接近于4，大于局部镦粗比的极限值3，故提出第2种方案，即强缩预镦冷挤压方案。在Forge有限元软件中建立了钢珠套螺杆20MnTiB合金结构钢的Hansel-Spittel流变应力模型，并对两套成形工艺方案进行了数值模拟。分析了零件成形过程中的等效应变分布、载荷-行程曲线以及损伤变化规律。结果表明：第2套方案的等效应变分布以及损伤分布均比第1套方案的分布均匀，且等效应变的最大值、总载荷以及损伤的最大值均小于第1套方案，因此，第2套方案为最优方案。通过对模拟结果进行试验验证，可以看出，应用第2套方案终镦成形的零件表面质量良好，金属填充饱满、无裂纹。

For the forming of steel ball sleeve screw for auto parts, two sets of process schemes were designed. In process 2 of the first scheme, when the part was upsetted with a large height-to-diameter ratio, the part was prone to the problems of uneven side for drum part and folding. Among them, the height-to-diameter ratio was close to four, which exceeded the local upsetting ratio limit value of three. Therefore, the second scheme was proposed, namely the forced shrinkage pre-upsetting cold extrusion scheme. Then, the rheological stress model Hansel-Spittel of 20MnTiB alloy structural steel for steel ball sleeve screw was established by finite element software Forge, and two sets of forming process schemes were numerically simulated respectively to analyze the equivalent strain distribution, load-displacement curve and damage variation law during the forming process of part. The results show that the equivalent strain distribution and damage distribution of the second scheme are more uniform than that of the first scheme, and the maximum values of equivalent strain, the total load and the damage are smaller than those of the first scheme. So the second scheme is the optimal scheme. Through the test verification of the simulation results, it proves that the surface of final upsetting part is good in quality with full metal filling and no crack.

基金项目：

国家自然科学基金资助项目(51575162)

杜昱青（1996-），女，硕士研究生 E-mail：DuyqStephanie@163.com 通讯作者：陈学文（1970-），男，博士，博士后，特聘教授 E-mail：chenxwdavid@163.com

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