圆钢管无凹模冲孔的凸模结构优化设计

Optimization design of punch structure for round steel pipe without die in piercing

针对钢管无凹模冲孔工艺中的平凸模、尖凸模等传统凸模结构无法解决的凹坑、塌陷量大等缺陷,提出一种新型螺旋型凸模结构。通过有限元模拟分析,研究了螺旋型凸模中上刃角β与下刃角α对冲裁力和冲裁质量的影响规律。采用正交试验设计研究螺旋型凸模中上刃角β和下刃角α的匹配关系,优化后的凸模结构参数为上刃角β为45°和下刃角α为40°。采用优化后的凸模结构参数进行模具设计,在可倾开式压力机上进行冲压试验,钢管冲孔的凹坑小、毛刺小,冲孔成形质量满足要求,试验结果与模拟结果一致。

For the deformation defects of scallops and large scale of collapses produced in the traditional fiat and sharp punch during non-die piercing process, a new spiral punch structure was presented. The influences of upper blade angle/3 and lower blade angle a of spiral punch on punching force and punching quality were studied by finite element simulation analysis. Moreover, the relationship between up- per blade angle/3 and lower blade angle a of spiral punch was researched based on orthogonal experimental design. Finally, the optimal parameters of punch structure were obtained, namely the upper blade angle is 45° and the lower blade angle is 40°. The die structure was designed by the optimized punch structure parameters, and the stamping tests were carried out by tilting open press. With only a little concave and burr, the piercing quality met production requirements. The test result is consistent with the simulation result.