冷却液管路法兰复合成形工艺控制研究

Process Control of Coolant Pipe Flange Composite Forming

目的增大法兰镦压成形面积,提高汽车冷却液管路法兰的加工质量,进而获得更好的汽车冷却系统密封性和整车安全性。方法在分析法兰自由端高度、管坯外径、管坯内径、接触摩擦因数等对传统法兰镦压成形影响的基础上,提出一种扩径-缩径-镦压的法兰复合成形工艺。一方面通过扩径提高法兰的成形面积,另一方面通过缩颈保证法兰与零件的正常配合,以此来突破传统镦压工艺的成形极限,并且通过DEFORM软件对扩径-缩径-镦压整个成形过程进行仿真分析,优化组合模具的结构参数。结果试制试验结果表明,使用传统工艺镦压成形的法兰直径最大可到达到23.2mm,而使用本文所提出的复合成形工艺可以使其直径增加到25.4 mm,法兰端面的接触面积由422.7 mm^(2)增加到506.7 mm^(2),提升约19.8%。结论采用扩径-缩径-镦压这种复合加工方式,可以在不降低加工质量的同时有效提高法兰面积的成形极限。该工艺可以为以后管路法兰的设计与生产工艺制定提供一定的参考。

The work aims to increase the area of flange upsetting and improve the processing quality of automobile coolant pipe flanges so as to obtain better sealing of the automotive cooling system and the safety of the vehicle.Based on the analysis of the influence of flange free end height,tube billet outer diameter,tube billet inner diameter and contact friction factor on tra-ditional flange upsetting-forming,a composite flange forming process of expanding-reducing-upsetting was proposed.The forming area of the flange was increased by expanding the diameter,and the normal matching between the flange and the part was ensured by reducing the neck,so as to break through the forming limit of the traditional upsetting process.DEFORM soft-ware was used to simulate and analyze the whole forming process of expanding,reducing and upsetting,and optimize the struc-tural parameters of the modular mold.According to the test results,the maximum diameter of the flange formed by the tradi-tional upsetting process could reach 23.2 mm,while the diameter could be increased to 25.4 mm by the composite forming process proposed in this paper,and the contact area of the flange end face increased by about 19.8%from 422.7 mm^(2) to 506.7 mm^(2).The composite machining method of expanding,reducing and upsetting can effectively increase the forming limit of flange area without reducing the machining quality.This process can provide some reference for the design and production process of pipeline flanges in the future.