锻压技术

基于数值模拟的20MnCr5钢薄壁壳体挤压工艺

英文标题：Extrusion process on 20MnCr5 steel thin-walled shell based on numerical simulation

作者：汪勇1 倪志兵2

分类号：TG376.3

出版年,卷(期):页码：2023,48(9):89-97

摘要：

以一种复杂薄壁壳体为研究对象，为解决其切削加工生产中材料切除量大、浪费严重的问题，实现近净成形，提出了一种多工位挤压配合少量切削的新工艺方案，材料利用率从35.49%增长至90.54%。通过Deform3D软件对3种不同冷挤压方案的制坯过程进行了数值模拟，对零件充填结果、金属流线形态、挤压成形力、等效应力等进行了全方位的对比。结果表明：采用方案1时，不仅能够有效地控制缺陷，使各工位零件成形质量较好、充填饱满，而且最大挤压成形力也要更小些。最后，进行了现场挤压试验，与模拟试验结果吻合，所有薄壁壳体均填充饱满，成形外观好，无刮花、裂纹等缺陷，尺寸检测结果均在要求范围内。

For a complex thin-walled shell, in order to solve the problem of large amount of material removal and serious waste in cutting production and realize the near net forming, a new process scheme of multi-station extrusion combined with a small amount of cutting was proposed, and the material utilization rate increased from 35.49% to 90.54%. Then, the blank-making processes of three different cold extrusion schemes were numerically simulated by software Deform-3D, and the filling effect of parts, streamline state, extrusion force and equivalent stress were compared in an all-round way. The results show that when the scheme 1 is adopted, not only the defects are effectively controlled, but also the forming quality of parts at each station is better, the filling is full, and the maximum extrusion force is also smaller. Finally, the on-site extrusion test was carried out, and the test results are consistent with the simulation test results. All the thin-walled shells are fully filled, the formed appearance is good without defects such as scratches and cracks, and the dimensional test results are within the required range.

基金项目：

江苏省高校自然科学研究项目（19KJB430025）

作者简介：汪勇（1986-），男，硕士，高级实验师 E-mail：hiwangyong@126.com

参考文献：

[1]卜军伟,蔡云.基于DEFORM的直齿圆柱齿轮精锻工艺[J].锻压技术,2021,46(11):43-48.

Bu J W, Cai Y. Precision forging process for spur gear based on DEFORM[J].Forging & Stamping Technology,2021,46(11):43-48.

[2]张华,陈建飞,杨建军,等.弧齿锥齿轮精锻成形工艺分析[J].机床与液压,2018,46(9):97-103,9.

Zhang H, Chen J F, Yang J J, et al. Analysis of spiral bevel gear of precision forging forming technology[J].Machine Tool & Hydraulics,2018,46(9):97-103,9.

[3]孙宪萍,刘强强,杨兵,等.杯-杆件有限元数值模拟成形工艺研究[J].热加工工艺,2015,44(23):122-126,129.

Sun X P, Liu Q Q, Yang B, et al. Study on forming process of cuprod part finite element numerical simulation[J].Hot Working Technology,2015,44(23):122-126,129.

[4]马世博,孙立科,张双杰,等.多台阶电机轴镦挤复合成形工艺[J].塑性工程学报,2021,28(7):28-35.

Ma S B, Sun L K, Zhang S J, et al. Upsetting extrusion composite forming process of multistep electromotor shaft[J].Journal of Plasticity Engineering,2021,28(7):28-35.

[5]兀光波.汽车蓄能器壳体温挤压仿真及参数优化[J].锻压技术,2021,46(12):159-164.

Wu G B. Simulation and parameter optimization on warm extrusion for automobile accumulator shell[J].Forging & Stamping Technology,2021,46(12):159-164.

[6]徐皓,刘江.高强度精密锻钢活塞锻造预锻模具设计及加工关键要点实践研究[J].塑性工程学报,2021,28(11):50-55.

Xu H, Liu J. Practice research on key points of preforging die design and machining for high strength precision forged steel piston forging[J].Journal of Plasticity Engineering,2021,28(11):50-55.

[7]于瑞,王中磊.铝合金汽车差速器外壳等温锻造成型研究[J].机械强度,2019,41(5):1158-1163.

Yu R, Wang Z L. Research on isothermal for forging of aluminum alloy automobile differential case[J].Journal of Mechanical Strength,2019,41(5):1158-1163.

[8]郑鹏辉,关悦,许吉星,等.A286高温合金十二角法兰面螺栓多工位冷镦成形工艺[J].制造技术与机床,2022，(7):45-50.

Zheng P H, Guan Y, Xu J X, et al. Multi station cold heading process of A286 superalloy twelve point flange bolt[J].Manufacturing Technology & Machine Tool,2022,(7):45-50.

[9]张东民,盛育东,张金玉,等.六角开槽螺母的冷镦工艺优化及数值模拟[J].机械设计与制造,2018,(3):191-194.

Zhang D M, Sheng Y D, Zhang J Y, et al. Numerical simulation and optimization for cold heading of hexagonal slot nut[J].Machinery Design & Manufacture,2018,(3):191-194.

[10]肖志玲,刘百宣,刘华,等.销钉多工位冷镦成形过程数值模拟及组织演变[J].热加工工艺,2014,43(17):119-121,124.

Xiao Z L, Liu B X, Liu H, et al. Numerical simulation and microstructure evolution on multistation cold heading of pin[J].Hot Working Technology,2014,43(17):119-121,124.

[11]肖兵.金属塑性成形理论与技术基础[M]. 成都：西南交通大学出版社, 2013.

Xiao B. Theoretical and Technical Basis of Metal Plastic Forming[M]. Chengdu: Southwest Jiaotong University Press, 2013.

[12]姜天亮.车用花键轴冷挤压成形及关键工艺参数优化研究[D].上海：上海工程技术大学,2019.

Jiang T L. Research on Cold Extrusion Forming and Optimization of Key Process Parameters of Vehicle Spline Shaft[D]. Shanghai: Shanghai University of Engineering Science,2019.

[13]胡建军. DEFORM3D塑性成形CAE应用教程[M]. 北京：北京大学出版社, 2011.

Hu J J.DEFORM3D Plastic Forming CAE Application Course[M]. Beijing: Peking University Press, 2011.

[14]李天兴,张迅雷,傅建中,等.轿车用齿坯精锻工艺参数与模具结构对金属流线的影响[J].机械传动,2015,39(10):154-157,175.

Li T X, Zhang X L, Fu J Z, et al. Influence of the technological parameter and die structure on metal flow line for precision forging car gear blank[J].Journal of Mechanical Transmission,2015,39(10):154-157,175.

服务与反馈：

【文章下载】【加入收藏】