薄壁六角螺母冷镦过程中模具磨损模拟分析及参数优化

Process Analysis and Parameter Optimization on Die Wear in Cold Heading for Thin-walled Hex Nut

以薄壁六角螺母工位四冷镦下冲头模具为例,基于Archard磨损模型采用DEFORM-3D软件对下冲头磨损进行分析。选取冲压速度、摩擦因子、模芯圆角、初始模具硬度4个主要影响因素,以降低模具磨损量为目标设计4因素5水平的正交试验。结果表明,冲压速度对该下冲头磨损影响最为显著,然后依次为摩擦因子、模具硬度、模芯圆角。通过极差和方差分析法,对4个因素进行优化,得出最优组合工艺参数,并验证了采用优化参数可大幅降低模具的磨损量,延长下冲头使用寿命。

The wear of the station four plunger of thin-walled hex nut was simulated based on the theory of Archard by finite element analysis software of DEFORM-3D.The orthogonal experiments were designed by selecting four impact factors such as pressing velocity, friction factor, mould core fillet radius and mould initial hardness and with the minimum wear of the die as the optimization target.The results show that the pressing velocity has a most significant influence on the plunger wear, following by friction factor, mould initial hardness and mould core fillet radius.By range analysis and variance analysis, the four impact factors were optimized to obtain the optimum combination process parameters, and it was proved that the wear amount of the die could be greatly reduced and the service life of the lower puncher could be prolonged by adopting the optimized parameters.