锻压技术

基于Deform-3D的汽车活塞轴套锻造过程分析及工艺改进

英文标题：Analysis on forging process and process improvement for automotive piston shaft sleeve based on Deform-3D

作者：李帆1 邢亚哲2

分类号：TG316.3

出版年,卷(期):页码：2024,49(8):13-20

摘要：

为解决一种汽车活塞轴套加工工序复杂、生产效率低的问题，提出了一种锻造结合切削的生产方式。为降低工艺风险，利用Deform-3D软件对锻造部分工艺进行了成形仿真，结果显示，在复合镦挤工位和终镦工位存在成形缺陷，并根据金属变形过程确定了缺陷成因。对锻造工艺方案进行了调整，包括坯料尺寸的改变以及各工位模具结构的优化；对调整后的锻造工艺重新进行了成形仿真，结果显示金属变形合理，零件填充完整，无缺陷产生，得到了满足预期的成形结果。基于仿真试验指导，完成了活塞轴套的生产实践，锻造结果较好，各工位均无缺陷产生，与预测结果一致，采用该工艺后不仅加快了活塞轴套的生产速度，而且材料利用率也由25.7%增长至77.0%，大幅缩减了成本。

In order to solve the problems of complex machining process and low production efficiency for a kind of automotive piston shaft sleeve, a production mode combining forging and cutting was put forward. In order to reduce the process risk, Deform-3D software was used to simulate the forging process. The results show that there are forming defects in the composite upsetting extrusion station and the final upsetting station. And the causes of the defects are determined according to the metal deformation process.The forging process scheme was adjusted, including the change of billet sizes and the optimization of die structures at each station. A new forming simulation was conducted on the adjusted forging process. The result shows that the metal deformation is reasonable, the filling of parts is complete, and there is no defects, achieving the expected forming results. Based on the guidance of simulation test, the production practice of piston shaft sleeve was completed. The forging results are good, and there are no defects in each station, which are consistent with the prediction results. The adoption of this process not only accelerates the production speed of piston shaft sleeves, but also increases the material utilization rate from 25.7% to 77.0%, significantly reducing costs.

基金项目：

作者简介：李帆（1982-），男，硕士，副教授 E-mail：lif1982@126.com

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