双向厚差小圆角带轮冲锻成形工艺

Stamping-forging hybrid forming of pulley parts with small fillet and thickness difference in two directions

对具有极小内外圆角、在横向和纵向均存在厚度差的带轮零件,进行冲锻成形。利用DEFORM-3D软件,对该带轮零件的冲锻成形工艺中的增厚工艺、极小圆角成形和整形过程进行分析,得到成形过程中金属的流动变形机制、等效应力及等效应变分布规律;确定合理的模具结构和参数,避免了冲锻成形过程中产生失稳折叠及凸凹不平等缺陷;根据模拟结果进行生产试制,验证了工艺的可行性和模拟的准确性。

Stamping-forging hybrid forming was proposed for pulley parts with small inner and outer rounded corners and thick-ness difference in the horizontal and the vertical directions. The thickening process, the forming of a very small fillet and shapingprocess included in the pulley part＇s stamping-forging hybrid forming were analyzed by DEFORM-3D software. The flow deform-ation mechanism and the distributions of equivalent stress and equivalent strain were obtained. By determining a reasonable moldstructure and parameters, the folding defects and the uneven surface were solved. The experimental results verified the feasibilityof the process and the accuracy of the simulatiom