汽车转向球销镦挤成形有限元分析与工艺

Finite element analysis and process on upsetting extrusion for automobile steering ball pin

采用有限元和实际物理试验相结合的方法,对汽车转向球销的近净成形工艺进行了研究。首先,根据转向球销的特点和塑性成形原理,确定了各特征的成形方式,基于材料许用变形量设计了两套五工位镦挤成形工艺方案;其次,通过压缩试验创建了40Cr钢在室温下的流动应力模型并导入了Deform-3D中,同时对两套方案分别进行了数值建模和成形仿真,并对充型效果、材料变形过程、等效应力分布、成形载荷变化情况等进行了比较,从而获得了更适合的方案;最后,根据模拟分析结论进行了转向球销的镦挤试验,结果表明:分析结果准确,成形工艺可靠,获得的转向球销充型饱满,外观较好,无明显缺陷,内部组织均匀,无折叠等问题,满足技术要求。

The near net forming process of automobile steering ball pin was studied by combining the finite element method and the actual physical test.Firstly,according to the characteristics of the steering ball pin and the principle of plastic forming,the forming mode of each characteristic was determined,and two sets of five-station upsetting extrusion forming process schemes were designed based on the allowable deformation amount of the material.Secondly,the flow stress model of 40Cr steel at room temperature was created by compression test and imported into Deform-3D.At the same time,the numerical modeling and forming simulation were carried out for the two schemes respectively,and the filling effect,material deformation process,equivalent stress distribution and forming load change condition were compared to obtain a more suitable scheme.Finally,the upsetting extrusion test of steering ball pin was carried out according to the simulation analysis results.The results show that the analysis results are accurate,the forming process is reliable,and the obtained steering ball pin has full filling,good appearance,no obvious defects,uniform internal organization,no folding and other problems,which meet the technical requirements.