基于数值仿真的台阶型定位销冷镦成形工艺优化

Optimization on cold upsetting process for step positioning pin based on numerical simulation

为降低成本、提高生产效率,摒弃传统凭借经验试模修模的方法,提出一种台阶型定位销的冷镦成形工艺方法。基于塑性成形理论,针对零件特征进行简单的模具设计,并分析影响零件成形的主要因素,结合DEFORM-3D有限元模拟及正交试验方法,设计上冲头速度、凹模锥角、凹模过渡圆角、摩擦系数、浮动凸模倒角的5因素4水平的正交试验,以零件在成形过程中模具所受载荷最小为优化目标,获得最优工艺参数。结果表明,当浮动凸模倒角为0. 3 mm、凹模锥角为10°、凹模过渡圆角为0. 1 mm、上冲头速度为6 mm·s-1、摩擦系数为0. 10时,模具的成形载荷最小。最后基于生产实际,与仿真结果进行对比,验证了试验的可行性。

In order to reduce cost and improve production efficiency, a cold upsetting process of step positioning pin was proposed, and the traditional method of die modification by experience was abandoned. Based on the theory of plastic forming, the simple die design was carried out according to the characteristics of parts, and the main factors affecting the forming of parts were analyzed. Combined with DE- FORM-3D finite element simulation and orthogonal test method, the orthogonal test of five factors and four levels was designed including speed of upper punch, cone angle of die, transition fillet of die, friction coefficient and chamfer of floating punch, and the optimum process parameters were obtained with the optimization objective of minimizing the load on the die during the forming process. The results show that when the chamfer of floating punch is 0. 3 mm, the cone angle of die is 10°, the transition fillet of die is 0. 1 mm, the speed of upper punch is 6 mm s _ 1 and the friction coefficient is 0. 10, the forming load of die is minimum. Finally, based on the actual produc tion ,the feasibility of the experiment is verified by comparing with the simulation results.