基于数值模拟的车用法兰连接件多工位冷锻工艺研究与改进

Research and improvement on multi-station cold forging process for vehicle flange connector based on numerical simulation

以车用法兰连接件为研究对象,根据其结构特点,提出了一种6工位冷锻工艺方案,并采用Deform-3D对各工位成形过程进行了建模分析。结果显示,该方案能够获得外观填充完整的法兰连接件,但存在材料折叠缺陷。基于此,在原方案基础上提出了两种改进方案并依次进行了模拟,分析了改进后方案的网格流线变化图,同时对比了两种改进方案的成形载荷大小。结果表明:两种改进后方案均能够解决材料折叠问题,采用改进方案1时,成形载荷相对更小,更利于降低模具受载,提高模具寿命。经实际试模可知,按改进方案1生产的各工位零件与模拟结果一致,成形完整,无裂纹、折叠等缺陷,工艺可靠,该优化方法对多工位锻造技术的发展具有一定的推广作用。

For the vehicle flange connector,based on its structural characteristics,a six-station cold forging process scheme was proposed,and the forming process of each station was modeled and analyzed by Deform-3D.The results show that this scheme can obtain the flange connector with a completely filled appearance,but there are material folding defects.Thus,two improved schemes based on the original scheme were proposed and simulated in turn,and the grid streamline change diagrams of the improved schemes were analyzed.At the same time,the forming loads of the two improved schemes were compared.The results show that the two improved schemes can solve the problem of material folding.When the improved scheme 1 is adopted,the forming load is relatively smaller,which is more conducive to reducing the mold load and increasing the mold life.The actual mold test shows that the parts produced according to the improved scheme 1 are consistent with the simulation results,the forming is complete,there are no defects such as cracks and folds etc.,and the process is reliable.Thus,this optimization method has a certain promotion effect on the development of multi-station forging technology.