锻压技术

汽车用薄壁管件预制坯设计及成形工艺模拟

英文标题：Preformed billet design and forming process simulation for automobile thin-walled pipe

作者：杨忠1 王彦凤2

分类号：TG376.2

出版年,卷(期):页码：2023,48(2):102-110

摘要：

为解决某型号汽车薄壁管件机械加工产生的材料利用率低、成本高等问题，提出了采用闭式挤压制坯后车削成形的加工方式。根据管件特征，对难成形部位结构进行了改进，设计了3种不同形状的预制坯，分别进行了成形模具的简化设计，并利用Deform-3D软件进行了数值分析。通过材料流动情况分析了各方案预制坯的成形过程，说明了各方案是否存在潜在缺陷，同时对比了不同方案材料利用率、成形载荷以及模具磨损。结果表明：方案1的材料利用率最高，但存在成形缺陷和模具损坏风险；方案2和方案3能够获得符合要求的预制坯形状，但方案2存在脱模不良的问题，而方案3在材料利用率、成形载荷以及模具磨损等方面均较为理想。最终通过方案3获得了符合要求的薄壁管件，生产效果好，解决了材料利用率低的问题。

In order to solve the problems of low material utilization rate and high cost caused by the machining for a certain type of automobile thin-walled pipe, a processing method of turning after closed extruded billet was proposed, and according to the characteristics of pipe, the structure of the difficult forming parts was improved. Then, three kinds of preformed billet with different shapes were designed, the simplified design of the forming mold was carried out, and the numerical analysis was carried out by software Deform-3D. Furthermore, the forming process of the preformed billet for each scheme was analyzed through the material flow situation, and the potential defects of each scheme were explained. At the same time, the material utilization rate, the forming load and the mold wear of different schemes were compared. The results show that scheme 1 has the highest material utilization rate, but there are forming defects and mold damage risks. Scheme 2 and scheme 3 can obtain the required preformed billet shape, but scheme 2 has the problem of poor demoulding, while scheme 3 is ideal in terms of material utilization rate, forming load and mold wear. Finally, the qualified thin-walled pipe is obtained through scheme 3, which has good production effect and solves the problem of low material utilization rate.

基金项目：

作者简介：杨忠（1971-），男，学士，高级讲师，E-mail：yangz197110@163.com

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