汽车三柱槽壳反挤压工序模拟及模具寿命提高

Simulation of backward extrusion process and improvement of mold life for automobile three-column groove shell

为了解决汽车三柱槽壳在实际反挤压过程中凸模磨损严重的问题,建立了Archard磨损模型,并导入Deform-3D软件中进行了反挤压过程仿真,以研究凸模的磨损规律。结果显示:凸模圆角处的温度最高,磨损深度最大,并且凸模载荷较大,均不利于凸模寿命的提高。分析了影响凸模寿命的因素,并将凸模最大磨损深度和最大载荷作为优化目标,借助正交试验法对凸模圆角半径、凸模斜角、坯料加热温度、模具预热温度、挤压速度等工艺参数进行了优选。研究了表面经涂层处理后的凸模的磨损情况,结果发现,涂层具有较好的降磨损能力,其中TiAlN涂层的降磨损能力最好。最后,经实际生产表明,改进后的凸模寿命为改进前的2倍多,极大地降低了模具成本。

In order to solve the problem of serious punch wear during the actual backward extrusion process for automotive three-column groove shell,an Archard wear model was established and imported into Deform-3D software to simulate the backward extrusion process,and the wear law of punch was studied.The results show that the temperature at the fillet corner of punch is the highest,the wear depth is the largest,and the punch load is larger,which are not conducive to improving the life of punch.The factors affecting the life of punch were analyzed,and taking the maximum wear depth and the maximum load of punch as the optimization objectives,the process parameters such as fillet radius of punch,bevel angle of punch,heating temperature of billet,preheating temperature of mold and extrusion speed were optimized by the orthogonal test methods.The wear of punch after surface coating treatment was studied.And the results show that the coating has a good wear-reduction ability,and the TiAlN coating has the best wear-reduction ability.Finally,the actual production shows that the life of the improved punch is more than twice that of the current one,which greatly reduces the cost of mold.