基于正交试验的车用螺母成形分析及模具磨损优化

Forming analysis and mould wear optimization on nuts for vehicle based on orthogonal test

以某车用锁紧螺母冷镦成形为研究对象,基于Archard磨损理论,采用有限元分析软件DEFORM-3D对模具磨损及成形载荷进行模拟分析。结果表明:制件成形符合工艺要求。为得到更优的成形效果,选取上冲头切入角、冲压速度、模具表面硬度、摩擦系数作为因素,设计正交试验,以降低模具磨损和成形载荷为目标对因素进行优选。分析得出各因素对结果的影响趋势,并通过综合考虑生产效率、能量消耗、设备磨损等因素,得到了最优工艺参数组合为上冲头切入角20°、冲压速度5 mm·s-1、模具表面硬度61 HRC、摩擦系数0. 12。采用最优参数重新进行模拟,上冲头使用寿命得到了大幅提升,并予以试模验证。

For the cold upsetting of locking nuts used in vehicle,based on Archard wear theory,the mould wear and forming loads were simulated and analyzed by finite element analysis software DEFORM-3 D. The result shows that the forming of parts fully meets the requirements of process. In order to get the better forming effect,the upper punch entrance angle,stamping speed,mould surface hardness and friction coefficient were chosen as factors,and the orthogonal test was designed to optimize the factors by reducing the mould wear and forming loads as the objective. Furthermore,the influence trend of each factor on the optimal objective was obtained by comprehensive consideration of production efficiency,energy consumption,equipment wear and other factors,and the optimal parameters with the upper punch entrance angle of 20°,the stamping speed of 5 mm·s-1,the die surface hardness of 61 HRC and the friction coefficient of 0. 12 were obtained. Finally,the life of punch was greatly improved by the optimum parameters,which was verified by the test.