Transactions of Materials and Heat Treatment

Title：Multi-station cold heading process and mold design for projection welding bolt

Authors： Wu Xiaoliang1 Cai Danyun2 Zhou Yupeng1 Cai Yafang2 3 Fang Jie2 3 Chen Wanji2

Unit： 1.Zili Fastening Technology (Huzhou) Co. Ltd. 2.Zhejiang University of Water Resources and Electric Power 3.China Jiliang University

KeyWords： projection welding bolt multi-station cold heading composite mold design metal flow load distribution

ClassificationCode：TG376.3

year,vol(issue):pagenumber：2024,49(6):81-87

Abstract：

In order to solve the problems of low forming efficiency and high cost caused by the combination process of multi-position upsetting-extrusion and punching-trimming of projection welding bolt, a six-station cold upsetting process for projection welding bolt was designed by recombining the original process, and each station of cold heading process for projection welding bolt was finite element simulated by Deform-3D. Then, the simulation results were analyzed from the perspectives of metal flow laws, filling fullness and load distribution status, which verified the reliability of the process. Furthermore, on this basis, the mold structure of each station was designed, and the problem of difficult clamp transmission caused by the short rod of the blank in this station was solved by designing the main mold core of trimming-extrusion composite mold as a floating structure. In addition, the support force was provided for the lower surface of the blank during trimming-extrusion process to ensure its flatness. The batch trial production results of projection welding bolts show that the surface of workpieces at each station is smooth, the filling is complete, and the dimensional tolerance is all within the required range. The new process increases the production efficiency by 80%, which can be used to guide the development of cold heading process and mold design for special-shaped short-rod bolt.

Funds：

浙江省重点研发计划项目(2020C01062)

作者简介：吴小亮（1987-），男，硕士,E-mail：wxl@zlftec.com;通信作者：蔡丹云（1975-），女，硕士，讲师,E-mail：740797754@qq.com

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