一种深孔钻成形工艺设计及数值模拟

Design and Numerical Simulation of a Deep Hole Drilling Forming Process

目的根据深孔钻的结构特点,进行零件工艺分析和成形工艺方案设计,通过工艺试验结果验证深孔钻成形工艺的可行性。方法首先,利用高温热压缩试验得到不同形变条件下深孔钻所用材料42CrMo合金钢的真应力-真应变曲线,并加以分析。其次,将试验数据导入Deform-3D材料库中,利用Deform-3D有限元模拟软件对深孔钻热挤压成形工艺方案进行数值模拟,分析成形过程中冲头的载荷-行程曲线以及形变过程中金属的流动规律、应力场分布、温度场分布和最终锻件的金属流线分布情况。最后,优化模拟结果进而得到成形工艺参数,进行深孔钻模具结构设计及工艺试验。结果试验模拟得到的深孔钻充填饱满,金属流线分布合理,与实际金属流线分布基本一致。在成形过程中,上冲头的最大载荷为4.43×10^(3)kN,工艺试验得到的锻件尺寸一致性较好,没有锻造缺陷。结论提出的深孔钻成形工艺是可行的,模具结构设计合理,可对该类型锻件的实际生产提供指导。

The work aims to analyze the parts process and design the forming process scheme according to the structural characteristics of deep hole drilling and verify the feasibility of the deep-hole drilling forming process through the process test results.Firstly,the true stress-strain curves of 42CrMo steel in different deformation conditions were obtained by high-temperature hot compression experiment.Then the results were analyzed,and the experimental data were imported into the Deform-3D material library.The numerical simulation of deep hole drilling hot extrusion process was carried out by Deform-3D finite element simulation software.The load-stroke curve of punch during forming,the metal flow law,stress field distribution,and temperature field distribution during deformation as well as the metal streamline distribution of final forging were analyzed.Finally,according to the simulated and optimized forming process parameters,structure design and process test of the deep hole drilling die were carried out.The simulated deep-hole drilling forgings were full of filling,and the distribution of metal streamline was reasonable,which was basically consistent with the actual distribution of metal streamline.In the forming,the maximum load of the upper punch was 4.43×10^(3)kN,and the forging obtained by the process test had good dimensional consistency and had no forging defects.The research results show that the deep hole drilling forming process proposed in this paper is feasible and the die structure design is reasonable,which can provide guidance for production of this type of forgings.