小型套管多工位冷镦挤成形工艺方案设计

Process design on multi-stage cold upsetting and extruding for small casing

针对小型套管类零件整体尺寸小、成形工步多、大批量加工的特点,提出小型套管类零件采用多工位高速冷镦挤成形加工的方法,并根据塑性成形理论,设计了两种六工位冷镦挤成形工艺方案,借助有限元分析软件DEFORM-2D模拟套管的成形过程,分析比较两种工艺方案中金属流动规律、成形载荷大小和锻造流线分布。模拟结果表明,采用两次反挤压+终镦的方案,其成形的套管充填饱满、无折叠,各工步成形载荷大小分布合理。通过工艺实验进行验证,结果表明数值模拟结果与实验结果相一致,验证了数值模拟的准确性,可为实际生产提供指导。

For the characteristics of small size,more forming steps and mass production of small casing part,the forming process of multistage cold upsetting and extruding for small casing part was proposed,and two schemes of six-stage cold upsetting and extruding process were designed based on the plastic forming theory.Then,the forming process of casing was simulated by the finite element software DEFORM-2D,and the metal flow laws,the forming load and the distribution of forging streamline distribution of two process schemes were analyzed.The simulation result shows that the casing is filled with fullness and without folding,and the distribution of forming load is reasonable by the‘twice backward extrusion+final upsetting’.The verification results of the process experiment indicate that the simulation results are consistent with the experimental results,and the accuracy of the numerical simulation is verified to provide guidance for the actual production.