基于正交试验的梭心冷挤压成形工艺研究及模具优化设计

Bobbin Cold Extrusion Forming Process and Mold Optimum Design Based on Orthogonal Test

为提高模具寿命,降低试模成本,文章对缝纫机梭心的冷挤压成形工艺和模具的设计优化进行了研究。为解决其传统工艺中端面不平的问题,设计了带有限流套的新模具结构;根据梭心的结构特点,提出了2种梭心冷挤压成形工艺方案,利用DEFORM-3D有限元模拟软件对工艺方案分别进行数值模拟,发现采用2个工步的成形方案模拟出的挤压件成形效果好;基于正交试验采用方差分析法和极差分析法共同分析,以成形载荷及其凸模磨损量的大小作为评判指标,获得最佳工艺参数组合;采用最佳的参数组合来探寻不同摩擦因数对成形载荷的影响、不同凸模初始硬度对凸模磨损量影响规律;通过优化后挤压件的损伤因子云图、等效应变云图以及折叠角云图分析,验证了优化模具的可行性。该研究对梭心零件的实际生产及其相似零件的生产提供了参考。

In order to improve the life of die and reduce the cost of mould test,the forming process and design method of the die were studied by taking the core of sewing machine as an example.In order to solve the problem that traditional process face is always uneven,a new die structure is designed with finite set.According to the structure of the bobbin,two kinds of bobbin cold extrusion forming processes are put forward,and the processes are simulated using the finite element simulation software DEFORM-3D.We found that the extrusion forming scheme by 2 step simulation of the forming effect of the common is good.The forming load and the size of the punch wear volume were used as the evaluation index and the best combination of process parameters were obtained based on orthogonal test analysis and extreme difference analysis.The optimal combination of parameters was utilized to explore the influence of different friction factor on the forming load,the different punch initial hardness of convex on the die wear influence.The optimized crush injury factor nephogram,equivalent strain cloud and cloud folding angle were analyzed and the feasibility of the rear die was verified.The research provides a reference for the actual production of spindle parts and the production of similar parts.