无刷直流电机转子供电保持架的冲压工艺

Stamping process on power supply cage for brushless DC motor rotor

将无刷直流电机转子供电保持架的加工工序分为7步,即工序1落料、工序2弯曲、工序3弯曲、工序4冲孔、工序5成形、工序6翻边、工序7攻丝。利用有限元模拟软件DEFORM-3D,分析了弯曲工序2的可行性,结果表明,在弯曲过程中不会出现断裂等不良现象。对弯曲工序2的工艺参数进行了正交试验,结果表明,当冲压速度为2.2 mm·s^-1、模具间隙为0.02 mm、摩擦系数为0.16、凹模圆角半径为1.0 mm时,工件回弹量最小。采用弯曲模具型面补偿,能有效地控制转子供电保持架的回弹量,对弯曲工序2而言,1.02倍的补偿值效果最好。在最优工艺参数组合作用下,并结合弯曲模具型面补偿,得到P1点的回弹量为0.28 mm,P2点的回弹量为0.23 mm,P3点的回弹量为0.08 mm。最后进行了试验验证,试验结果与模拟结果吻合较好。

The manufacturing process of power supply cage for brushless DC motor rotor was divided into seven steps,namely,process 1 blanking,process 2 bending,process 3 bending,process 4 punching,process 5 forming,process 6 flanging and process 7 tapping,and the feasibility of process 2 bending was analyzed by the finite element simulation software DEFORM-3 D. The results show that no fracture and other adverse phenomena during the bending process occur. Then,the process parameters of process 2 bending were optimized by the orthogonal test,and the smallest springback of workpiece is obtained with the punching speed of 2. 2 mm ·s^（-1）,the die clearance of0. 02 mm,the friction coefficient of 0. 16 and the die fillet radius of 1.0 mm. Furthermore,the springback of power supply cage for rotor is controlled effectively by compensating the surface of bending die,and the best effect of the process 2 bending is 1. 02 times the compensation value. Under the action of the optimal combination of process parameters and combining the compensating of bending die surface,the springback of point P1,point P2 and point P3 are 0. 28,0. 23 and 0. 08 mm respectively. Finally,the tests were conducted,and the experiment results are similar to the simulation results.