基于数值模拟的汽车非标轴套塑性成形工艺研究及优化

Research and optimization on plastic forming process for automobile non-standard shaft sleeve based on numerical simulation

以一种非标轴套为研究对象,针对切削加工制造方式工序多、效率低和材料成本高等问题,提出了一种塑性加工工艺并展开了研究。通过冷压缩试验获得了实际成形材料的流变特性,并基于此利用Deform-3D软件对非标轴套的塑性成形工艺进行了数值模拟,分析了不同工位的材料流动情况,预知了轴套头部的折叠缺陷以及缺陷产生的阶段,并进行了试验验证;对工位3零件外形进行了改进,并结合浮动式模具结构有效解决了轴套头部的折叠缺陷;最后,根据研究结果重新对非标轴套进行了生产制作,获得的轴套与预期一致,头部无折叠缺陷,外观良好,验证了模拟分析的准确性,且轴套尺寸能够达到生产要求,与切削加工相比,不仅能够实现高速、批量生产,材料利用率也提高至86.1%。

For a non-standard shaft sleeve,aiming at the problems of multiple processes for manufacturing method,low efficiency and high material cost in cutting process,a plastic processing process was proposed and studied.The rheological properties of the actual forming material were obtained by the cold compression test,and based on this,the plastic forming process of non-standard shaft sleeve was numerically simulated by using Deform-3D software,the material flow condition at different stations was analyzed,the folding defect at the head of shaft sleeve and the stage of defect generation were predicted,and the test was carried out to verify.Furthermore,the shape of part in station 3 was improved,and the folding defect at the head of shaft sleeve was effectively solved by combining with the floating die structure.Finally,according to the research results,the non-standard shaft sleeve was re-produced,and the obtained shaft sleeve was consistent with the expectation without folding defects at the head and with a good appearance,which verified the accuracy of the simulation analysis.The results show that the size of shaft sleeve can meet the production requirements.Compared with the cutting process,it can not only achieve high-speed batch production,but also improve the material utilization rate to 86.1%.