锻压技术

基于计算机数值分析的一种汽车非标件自动化冷镦工艺

英文标题：An automatic cold upsetting process for automobile non-standard parts based on computer numerical analysis

作者：柏世兵

关键词：Mg1.8Al0.2Ni镁基电池合金多向等温锻造工艺锻造温度耐腐蚀性能充放电循环稳定性

分类号：TG386.3

出版年,卷(期):页码：2022,47(9):30-38

摘要：

为改变一种汽车非标件当前生产工艺工序多、生产效率低且产品性能差异大的现状，提出了两种自动化冷镦方案。运用Deform-3D建立了10B21钢的Johnson-Cook本构模型，同时基于该模型对两种方案各工位零件进行了模拟成形，分析了材料变形规律、等效应力分布以及载荷情况，进行了工艺检查和择优，确定了最终成形方案，即下料—减径和预成形内孔—预镦头部—镦花形头—头部整形—头部终成形—冲孔，并完成了工艺试验。生产试验表明:有限元分析结果准确，优选获得的冷镦工艺可靠，能够实现该非标件的批量生产，获得的零件成形完整、表面质量好，无刮料、折叠、坑洼等问题，尺寸精度达到了生产要求。

In order to change the current situation of multipre processes, low production efficiency and large differences of product performance in curvent production process for an automobile non-standard part, two kinds of automatic cold upsetting schemes were proposed, and the Johnson-Cook constitutive model of 10B21 steel was established by Deform-3D. Then, based on the model, the simulated forming of the parts in each station for the two schemes were conducted, and the deformation law, equivalent stress distribution and load situation of the material were analyzed. Furthermore, the process inspection and optimization were carried out, and the final forming scheme was determined, namely, blanking-diameter reducing and inner hole pre-forming-head pre-upsetting-flower head upsetting-head shaping-head final forming-punching, and the process test was completed. Production tests show that the finite element analysis results are accurate, the optimized cold upsetting process is reliable, and the mass production of the non-standard parts can be realized. The obtained parts have complete forming, good surface quality and no problems of scraping, folding, potholes and so on, and the dimensional accuracy meets the production requirements.

基金项目：

重庆市教育委员会项目（193299）;重庆市级规划项目(2020-GX-397)

柏世兵（1983-），男，硕士，副教授 E-mail：bsb198309@163.com

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