| 引用本文: | 陈凌翔,李月超.汽车六角球头冷锻工艺优化与数值仿真[J].材料科学与工艺,2020,28(5):75-82.DOI:10.11951/j.issn.1005-0299.20190227. |
| CHEN Lingxiang,LI Yuechao.Optimization and numerical simulation of cold forging process for automobile hexagonal ball head[J].Materials Science and Technology,2020,28(5):75-82.DOI:10.11951/j.issn.1005-0299.20190227. |
|
| 摘要: |
| 冷锻成形工艺是一种少无切削的净近成形工艺,以其精度高、生产效率高、低耗节能等优点,大量使用在汽车零配件的生产。六角球头销是汽车转向系统中的关键零件,其六角成形的质量直接影响到产品的使用性能。本文针对六角一次成形发生镦锻失稳问题,基于金属塑性成形理论,分析在镦锻过程中的金属流动,提出采用预成形工艺。根据产品结构,提出了大V锥形、锥形、锥六角形三种预成形工艺方案,采用DEFORM-3D对六角头成形方案进行数值仿真。为了得到最优参数,通过建立优化数学模型,对数值仿真获取的应力应变、损伤值分布、载荷进行优化得到最优方案。结合有限元数值分析对比分析三种方案,得到了预成形为锥形的成形效果最好,材料流动更为合理。经生产试验证明,通过预成形为锥形生产的六角头充填饱满,无不良缺陷,对生产同类型的成形工艺具有一定的参考价值。 |
| 关键词: 冷镦锻 六角球头 数值仿真 数学模型 工艺优化 |
| DOI：10.11951/j.issn.1005-0299.20190227 |
| 分类号:TH162.1 |
| 文献标识码:A |
| 基金项目: |
|
| Optimization and numerical simulation of cold forging process for automobile hexagonal ball head |
|
CHEN Lingxiang,LI Yuechao
|
|
(Automotive Engineering College,Xinxiang Vocational and Technical College,Xinxiang 453000,China)
|
| Abstract: |
| Cold forging process is a kind of net near forming process without cutting. It is widely used in the production of auto parts because of its high precision, high production efficiency, low consumption and energy saving. The hexagon ball pin is the key part of the automobile steering system. The quality of hexagon forming directly affects the performance of the product. Based on the theory of metal plastic forming, this paper analyzes the metal flow in the process of upsetting, and puts forward the pre forming technology. According to the product structure, three kinds of pre forming process schemes are put forward, which are large V cone, cone and cone hexagon. In order to obtain the optimal parameters, the stress-strain, damage value distribution and load obtained by numerical simulation are optimized by establishing the optimal mathematical model. Combined with the finite element numerical analysis and comparative analysis of three schemes, it is found that the forming effect is the best when the preform is tapered, and the material flow is more reasonable. It is proved by production test that the hexagon head produced by pre forming is full and free of defects, which has certain reference value for the production of the same type of forming process. |
| Key words: cold heading Hexagonal ball head numerical simulation mathematical model process optimization |
