电动工具异形输出轴镦挤成形工艺研究

Study on forming process of power tools profiled output shaft

针对电动工具异形输出轴结构的成形特点,提出变工作带正挤异形杆部和闭式镦粗头部台阶的两工步成形工艺方案,基于Deform-3D有限元分析软件建立挤压、镦粗工艺过程的有限元模型,分析了成形过程的金属材料流动状况、成形载荷,模拟结果表明整个成形过程金属流动均匀、合理。基于模拟和计算结果,设计了模具并选取200t液压机作为实验设备,获得表面完整、无折叠的合格制件。实验和模拟结果证明方案设计正确,可以投入生产。

Based on the analysis of the structure for power tools profiled output shaft, two steps forming program of variable bearing lengths forward extrusion for profiled pole and closed upsetting for head steps was proposed. A 3 D coupled thermo-mechanical finite element model was created and analyzed by the software Deform-3D. The data of met al flows and forming load in the whole process were acquired. The simulation shows that metal flows uniformly and reasonably. Based on the simulation and calculation, the die was designed, 200 t hydraulic press was selected to be the experiment equipment and a well filling extruded part without overlap defects was obtained. The experiment and simu lation demonstrate that the program is feasible.