金属薄板台阶断面件可冷压加工性的试验研究

An Experiment Study on Workability for Cold Pressure Forming of Sheet Metal Part with Step Cross-section

基于冲压分离工序只能实现板类零件的分离成形,且其分离断面为直壁形状,而现今生产实际中又提出了一种内孔和外缘均有台阶断面形状的薄板零件的要求,研发了一种以普通冲裁的冲压工艺为基础,与挤压、压印等冷锻工艺组合的板料成形新工艺,成形出了这种新型结构的薄板零件。利用DEFORM-3D等通用软件进行了数值模拟分析,获得了该类零件成形过程中的一些变形力学行为规律,并提出了其内孔与外缘之合理壁间距概念及其数值大小的设计原则,设计制造了一副冲压冷锻组合模,用铝质动力电池盖零件以及铜板材料进行了工艺试验验证。

The separating processes of stamping can be used only for separation and forming of sheet metal part, and the cross-section is vertical. In modern manufacturing, a new requirement of sheet metal part with step cross-section in both the inner hole and outer edge has been proposed. Aiming at this new sheet metal part type, a new flow control forming process of sheet metal has been excogitated, which based on blanking process of general stamping and combined with cold forging processes such as extrusion and coining, etc. With utilization of this new process, the newly structural sheet metal parts can be manufactured. The numerical simulation was carried out by u- sing DEFORM -3D CAE software, and both deformation and mechanics rules were analyzed,then a new conception of optimal distance between the step walls of inner hole and outside edge was proposed as well as the design principle for its numerical value was inferred. Furthermore, a mould ＆ die set for combination of stamping ＆ cold forging had been designed and manufactured, the technologic experiments with aluminum plates part and coppr sheet were taken for validation.