锻压技术

车用法兰连接件冷成形工艺研究及优化

英文标题：Research and optimization on cold forming process for vehicle flange connected part

作者：邱尚磊1 阎峻2

分类号：TG386.1

出版年,卷(期):页码：2021,46(6):106-111

摘要：

首先，以某车用法兰连接件为研究对象，根据其结构提出了一种拉深、冲孔、翻边、冷镦挤的多工位成形工艺，采用有限元软件Deform-3D对冷镦挤工位进行了模拟分析，并设计了3种不同结构坯料的方案，基于数值模拟结果，获得了最佳成形方案，即采用锥形坯料；其次，为获得冷镦挤的最优工艺参数，以上冲头、固定块以及凹模承受载荷的最小值为优化目标，建立了关于凹模圆角半径、摩擦因数、镦挤速度、固定块圆角半径的4因素3水平正交试验表，并结合有限元分析了各试验因素的关键程度，采用极差分析获得了法兰连接件的最优镦挤工艺参数组合，即凹模圆角半径为8 mm、摩擦因数为0.1、镦挤速度为30 mm·s-1、固定块圆角半径为6 mm；最后，通过实际试生产，获得了符合要求的法兰连接件，验证了方案的可行性。

For a vehicle flange connected part, a multi-station forming process of drawing, punching, flanging and cold upsetting extrusion was proposed based on the structure, and the cold upsetting extrusion station was simulated and analyzed by the finite element software Deform-3D. Then, three schemes of blanks with different structures were designed, and based on the numerical simulation results, the best forming scheme was obtained, that is, the taper blank was used. Furthermore, in order to obtain the optimal process parameters of cold upsetting extrusion, taking the minimum value of load for upper punch, fixed block and die as the optimization objectives, four factors and three levels orthogonal test table on die fillet radius, friction coefficient, upsetting extrusion speed and fixed block fillet radius were established, and the key degree of each test factor was analyzed by combining finite element method. The optimal upsetting extrusion process parameters of the flange connected part were obtained by range analysis with the die fillet radius of 8 mm, the friction coefficient of 0.1, the upsetting extrusion speed of 30 mm·s-1, and the fixed block fillet radius of 6 mm. Finally, through the actual trial production, the flange connected parts that meet the requirements were obtained, and the feasibility of the scheme was verified.

基金项目：

邱尚磊（1985-），男，学士，讲师 E-mail：2703637338@qq.com

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