锻压技术

基于Deform-3D的汽车发动机十二角轴套多工位冷镦技术

英文标题：Multi-station cold heading technology for automotive engine twelve corner shaft bushing based on Deform-3D

作者：张志武波涛张国新李文涛韩龙海

单位：河北机电职业技术学院

分类号：TG316.3；O242.21

出版年,卷(期):页码：2024,49(6):52-60

摘要：

汽车发动机十二角轴套由于结构复杂导致生产工序较多，普遍存在效率不高、耗材多、质量不稳定等生产难题，为此，旨在开发一种适用于该轴套的多工位冷镦工艺。首先，对轴套结构进行分析，制定了两种符合成形理论的冷镦工艺方案，并完成了多工位模具结构的简单设计与建模；其次，在Deform-3D中建立了轴套材料SCM420钢的Norton-Hoff流动应力模型，并依此对两种工艺进行了成形仿真，具体分析了金属的变形过程，同时比较了等效应力分布结果、载荷变化情况以及材料的损伤程度，从而提高了最终工艺的可靠性；最后，通过实际冷镦试验对仿真结果进行了验证，完成了十二角轴套的试生产。制造的轴套棱角饱满、成形完整，外观和内孔质量较好，无裂纹和划伤等缺陷，且尺寸精度高，能够满足使用要求。

The twelve corner shaft bushing of an automotive engine has many production processes due to its complex structure, which generally has production difficulties such as low efficiency, high material consumables and unstable quality. So it is aimed for development of a multi-station cold heading process suitable for this shaft bushing. Firstly, the structure of shaft bushing was analyzed, two cold heading process schemes corresponding with the forming theory were developed, and the simple design and modeling of multi-station die structure were completed. Secondly, the Norton-Hoff flow stress model of shaft bushing material SCM420 steel was established by Deform-3D, and the forming simulation of the two processes was carried out according to this. Then, the deformation process of metal was analyzed in detail, and the equivalent stress distribution results, the load change situation and the damage degree of material were compared to improve the reliability of the final process. Finally, the simulation results were verified through the actual cold heading test, and the trial production of the twelve corner shaft bushing was completed. The results show that the manufactured shaft bushing has full edges and corners, complete forming, good appearance and inner hole quality, no defects such as cracks and scratches and high dimensional accuracy, which meet the usage requirements.

基金项目：

河北省高等学校科学技术研究青年基金资助项目（QN2022105）

作者简介：张志（1977-），男，硕士，副教授,E-mail：zhangzzzhi@126.com

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