锻压技术

减震器深孔活塞套管冷锻工艺数值分析及模具结构优化

英文标题：Numerical analysis on cold forging process and optimization on die structure for deep hole piston sleeve of shock absorber

作者：王晓伟

单位：濮阳职业技术学院机电与汽车工程学院

关键词：深孔活塞套管冷精锻金属流线模具结构模具磨损

分类号：TG316.3

出版年,卷(期):页码：2023,48(3):34-42

摘要：

以减震器深孔活塞套管为研究对象，针对其因传统切削工艺材料利用率低而造成的生产成本高的问题，开发了两套少无切削的冷精锻成形工艺。首先，基于Deform-3D仿真平台分析了两种成形方案的成形结果，从填充效果和流线分布两个方面说明了冷精锻工艺的切实可行性；其次，比较了两种成形方案的模具结构、等效应力、锻后零件温差、成形力以及模具磨损，优选出更加可靠、简单的冷精锻方案；而后，对工艺进行了完善，分析了平锥头下冲棒、锥头下冲棒以及球头下冲棒的使用效果；最后，综合模拟分析结果进行了深孔活塞套管的冷锻试验。试验结果表明：制件填充充分，外观好，无坑洼、缺肉等缺陷，零件尺寸测量结果满足要求，批量化生产稳定，生产成本明显降低。

For the deep hole piston sleeve of shock absorber, aiming at the problem of high production cost caused by the low material utilization rate of traditional cutting process, two sets of cold precision forging process with less cutting or no cutting were designed. Firstly, the forming results of the two forming schemes were analyzed based on Deform-3D simulation platform, and the practical feasibility of cold precision forging process was demonstrated from the aspects of filling effect and streamline distribution. Secondly, the mold structure, equivalent stress, temperature difference of parts after forging, forming force and mold wear of the two forming schemes were compared, and a more reliable and simple cold precision forging scheme was optimized. Then, the process was perfected, and the use effects of lower punches with flat cone head, cone head and ball head were analyzed. Finally, the cold forging test of deep hole piston sleeve was carried out based on the simulation analysis results. The test results show that the parts are fully filled with good appearance, no potholes, lack of meat and other defects, the dimension measurement results of the parts meet the requirements, the mass production is stable, and the product cost is significantly reduced.

基金项目：

作者简介：王晓伟（1982-），男，硕士，讲师 E-mail：wxw391223@163.com

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