锻压技术

基于有限元分析的汽车六角开槽螺母冷锻成形分析与优化

英文标题：Analysis and optimization on cold forging for automotive hexagonal slotted nut based on finite element analysis

作者：张研吴排霞范龙

分类号：TH162+.1

出版年,卷(期):页码：2025,50(6):33-41

摘要：

以六角开槽螺母为研究对象，针对生产速度慢、耗材高、使用寿命短、断裂问题严重等情况，对其多工位冷锻成形工艺进行了研究。首先，根据塑性成形原理，按照各特征的不同成形顺序，为六角开槽螺母设计了两种合适的成形方案；其次，基于实况利用Deform-3D完成了模拟，对两方案各工位零件的内部成形质量和外形完整性进行了具体分析，并基于材料的断裂模型预测了断裂风险；最后，通过应力分析、载荷对比等完成了工艺的优选，同时完成了优选工艺的模具结构设计、制造与试模。结果表明：模拟预测准确，各工位零件冷锻效果好，薄壁、凹槽、六角等特征成形饱满，无划痕、裂纹、坑洼等问题，且螺母尺寸满足设计要求，与现工艺相比，螺母的性能、生产效率等均得到较大提升。

For hexagonal slotted nut, the multi-station cold forging process was studied in view of slow production speed, high consumables, short service life and serious fracture problems. Firstly, according to the principle of plastic forming and the different forming sequences of each feature, two suitable forming schemes were designed for hexagonal slotted nut. Secondly, based on the actual situation, the simulation of forming processes was completed by Deform-3D. And the internal forming quality and external integrity of the parts in each station of the two schemes were specifically analyzed, and the fracture risk was predicted based on the fracture model of material. Finally, the process optimization was completed by stress analysis, load comparison, etc., and the die structure design, manufacturing and trial production of the optimized process were also completed. The results show that the simulation prediction is accurate, the cold forging effect of part in each station is good, the thin-walled, grooved, hexagonal and other features are fully formed without scratches, cracks, potholes and other problems, and the nut size meets the design requirements. Thus, compared with the current process, the performance and production efficiency of the nut are greatly improved.

基金项目：

2021年度河南省高等教育教学改革研究与实践项目（2021SJGLX666）

作者简介：张研（1982-），男，硕士，讲师,E-mail：zhangyanz82@163.com

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