制动器调节螺母精密成形工艺

Precsion forming process of brake adjust-nut

通过研究盲孔中空结构且孔口直径较小的42CrMo4中碳合金钢制动器调节螺母的成形工艺,提出一种加工流程简单、成本较低的精密成形方案,以提高产品竞争力。针对该零件的特殊结构,设计了两种多工序成形工艺方案,分别为减径工艺方案和镦粗工艺方案,并采用有限元分析软件DEFORM-3D对两种成形工艺方案分别进行模拟,然后对不同成形过程中的金属流线分布、载荷和锻件结构进行对比研究,得到一种融合了温锻、反挤压(冷)、减径等成形方式的多工序精密成形工艺,并通过试制验证了该精密成形工艺的可行性。为多台阶、变截面、芯部中空、含有较多合金成分和碳含量的零件的成形提供了一种精密成形思路。

Through the study on the forming process of brake adjust-nut with hollow blind structure,small hole diameter for medium carbon alloy steel 42 CrMo4,a precise forming scheme with simple process and low cost was proposed to improve product competitiveness.Two kinds of forming processes were designed based on its special structure,such as reducing process scheme and upsetting process scheme,which were simulated by finite analysis software DEFORM-3 D,the metal streamline distributions,loads and forgings structures were studied and compared in different forming processes.At last,a multi-operation precision forming process which combined warm forging,cold backward extrusion,reducing and other forming methods was obtained.Furthermore,the multiple precision forming process was verified by manufacture.A precision forming idea is provided for the formation of the product with multi-step,variable cross-section,core hollow and much more alloy compositions and carbon content.