锻压技术

航空电机薄壁异形孔零件刷盒冷挤压成形工艺

英文标题：Cold extrusion forming process for brush box of thin-walled part with special-shaped hole in aviation motor

单位：1.贵州师范大学机械与电气工程学院 2.重庆文理学院材料科学与工程学院 3.华中科技大学材料科学与工程学院

分类号：TG376.3

出版年,卷(期):页码：2025,50(2):85-93

摘要：

针对航空直流电机刷盒中薄壁异形孔壁厚不均、对称度高等特点，设计了冷挤压成形工艺方案。运用模拟分析软件Deform-3D对异形孔复合挤压过程进行仿真，分析了变形金属流动特点、3个变形区的最大主应力状态及损伤值。结合正交实验,以预制坯孔径和凸模前端直径为影响因素，建立了2因素3水平正交实验方案，分析了不同工艺参数组合下的异形孔成形情况，极差分析结果表明：预制坯孔直径为Φ5.5 mm、凸模前端直径为Φ5.0 mm为最优工艺参数组合，此组合下圆孔与长方孔过渡圆弧面损伤值最小，薄壁孔产生裂纹倾向最小。在液压机上进行工艺实验验证，挤压件成形质量良好，达到设计要求。

For the characteristics of uneven wall thickness and high symmetry of thin-walled and special-shaped hole in the brush box of aviation DC motors, the cold extrusion process scheme was designed. Then, the composite extrusion process of special-shaped holes was simulated by the simulation analysis software Deform-3D, and the flow characteristics of deformed metal and the maximum principal stress states in the three deformation zones as well as the damage values were analyzed. Furthermore,

combined with orthogonal experiment, taking the diameters of preformed blank hole and front end of punch as the influence factors, the orthogonal experiment scheme of two factors and three levels was designed, and the forming of special-shaped hole was analyzed.

The results of range analysis show that the optimal process parameter combination is that the diameter of preformed blank hole is Φ5.5 mm and the front end diameter of punch is Φ5.0 mm,under this condition, the damage value of transition circular arc surface between circular and rectangular holes is the smallest, and the cracking tendency of thin-walled hole is the smallest.

The process experiments are conducted on the hydraulic press, and the forming quality of extrusion part is good and meets the design requirements.

基金项目：

贵州省自然科学基金资助项目（黔科合基础[2020]1Z050）

作者简介：袁玉红（1971-），女，硕士，副教授,E-mail：1026970310@qq.com;通信作者：刘詹（1999-），男，硕士研究生,E-mail：1095474693@qq.com

参考文献：

[1]夏巨谌.典型零件精密成形[M].北京:机械工业出版社,2008.

Xia J C. Precision Forming of Typical Parts[M]. Beijing：China Machine Press,2008.

[2]洪慎章.实用冷挤压模设计与制造[M].北京.机械工业出版社,2010.

Hong S Z. Design and Manufacture of Practical Cold Extrusion Die[M].Beijing：China Machine Press,2010.

[3]王忠雷, 赵国群. 精密锻造技术的研究现状及发展趋势[J].精密成形工程, 2009, 1 (1): 32-38.

Wang Z L, Zhao G Q. Recent condition and developing trends of precise forging technology[J]. Journal of Netshape Forming Engineering, 2009, 1 (1): 32-38.

[4]匡余华.异形孔台阶齿轮冷挤压工艺与模具优化设计[J].模具工业,2007(12):60-62.

Kuang Y H. Cold extrusion process and optimization design of die for step-shaped gear with profile hole [J]. Die & Mould Industry,2007(12):60-62.

[5]伍太宾,严学书.深孔黄铜火帽壳体的冷挤压成形研究[J].兵器材料科学与工程,2005(6):34-36.

Wu T B, Yan X S. Research on cold extrusion of primer body made of brass[J]. Ordnance Materials Science and Engineering,2005(6):34-36.

[6]束昊,周燕妮,郑伟刚.球面滑履冷挤压工艺的数值模拟分析与研究[J].锻压装备与制造技术,2017,52(1):99-103.

Shu H,Zhou Y N,Zheng W G. Numerical simulation analysis and research of cold extrusion technology for spherical slippery foot-step[J].China Metalforming Equipment & Manufacturing Technology,2017,52(1):99-103.

[7]姜天亮,龚红英,赵小云,等.基于DEFORM-3D的花键轴坯料结构尺寸优化设计[J].塑性工程学报,2020,27(6):111-115.

Jiang T L, Gong H Y, Zhao X Y, et al. Optimum design of spline shaft blank structure dimension based on DEFORM-3D [J]. Journal of Plasticity Engineering, 2020,27 (6): 111-115.

[8]赵德颖,张连东,朱恩领,等.挤压工艺参数对枝杈类锻件折叠缺陷的影响[J].塑性工程学报,2018,25(2):99-105.

Zhao D Y, Zhang L D, Zhu E L, et al. Effect of extrusion processing parameters on folding defects in branch-type forging[J].Journal of Plasticity Engineering,2018,25(2):99-105.

[9]Lin H S, Lee C Y,Li W S. Piercing and surface-crack defects in cold combined forward-backward extrusion[J]. Applied Sciences, 2021,11(9):3900.

[10]董文正,王丹,林启权,等.某电机齿轮冷挤压裂纹形成机理研究[J].塑性工程学报,2024,31(8):208-215.

Dong W Z, Wang D, Lin Q Q, et al. Study on crack formation mechanism of a motor gear in cold extrusion [J].Journal of Plasticity Engineering,2024,31(8):208-215.

[11]Kalyuzhnyi V L, Alieva L I, Kartamyshe D A, et al. Simulation of cold extrusion of hollow parts[J]. Metallurgist, 2017,61(55):359-365.

[12]于永泗,齐民.机械工程材料 [M]. 8版.大连:大连理工大学出版社,2006.

Yu Y S, Qi M.Materials for Mechanical Engineering[M]. 8th Edition.Dalian:Dalian University of Technology Press, 2006.

[13]GB/T 228.1—2021,金属材料拉伸试验第1部分:室温试验方法[S].

GB/T 228.1—2021, Metallic materials—Tensile testing—Part 1: Method of test at room temperature[S].

[14]陈学文,王进,陈军,等.基于最小损伤值的齿轮毛坯锻造成形过程工艺参数优化设计[J].上海交通大学学报,2005,39(7):1070-1076.

Chen X W, Wang J, Chen J, et al.Optimization design of process parameters of gear blank forging process based on minimum damage value[J].Journal of Shanghai Jiao Tong University,2005,39(7):1070-1076.

[15]权国政,佟莹,周杰.不同温度及应变速率条件下AZ80镁合金临界损伤因子研究[J].功能材料,2010,41(5):892-894，898.

Quan G Z,Tong Y,Zhou J. A study on the critical damage factor of AZ80 magnesium alloy under different temperatures and strain rates [J].Journal of Functional Materials,2010,41(5):892-894，898.

[16]刘佳琪,陈学文,皇涛,等.2A12铝合金临界损伤值测定及试验验证[J].塑性工程学报,2020,27(1):131-137.

Liu J Q,Chen X W, Huang T, et al. Measurement and experimental validation of critical damage value for 2A12 aluminum alloy [J].Journal of Plasticity Engineering,2020,27(1):131-137.

服务与反馈：

【文章下载】【加入收藏】