基于有限元分析的螺套冷锻工艺改进

Improvement of cold forging process for screw sleeve based on finite element analysis

为解决通过冷锻配合机加工生产EPB螺套时暴露出的生产率低、成本高等问题,为其重新制定了一种全自动冷锻方案,并以实际材料作为试验前提,通过Deform-3D进行了全过程数值仿真,结果发现存在金属折叠缺陷,通过金属流动分析确定了折叠缺陷产生于镦头工位,产生原因为金属弯曲。为消除缺陷,在原工艺基础上进行了优化,提出通过“镦粗+反挤压+浮动反挤压”成形方案来替代原来的“正挤压+反挤压+镦头”成形方案。仿真结果表明,工艺优化后折叠缺陷完全消除,各工位零件外形完整,截面流线连续,螺套质量好。实际锻造试验表明,全过程均未出现成形缺陷,与预测情况符合,并且螺套质量稳定,生产效率和效益显著提升,达到了企业的预期标准。

In order to solve the problems of low productivity and high cost in the production of EPB screw sleeve by cold forging combined with machining,a fully automatic cold forging scheme was redefined,and based on the test using the actuel material,the whole process was simulated by Deform-3D.Then,the results shows that there are metal folding defects,and it is determined that the folding defect occurre at the heading station and the cause is metal bending by analyzing the metal flow.Furthermore,in order to eliminate the defect,the optimization was carried out on the basis of the original process,and the forming scheme of“upsetting+backward extrusion+floating back extrusion”was proposed to replace the original forming scheme of“forward extrusion+backward extrusion+heading”.The simulation results show that after the process optimization,the folding defects are completely eliminated,and the shape of part at each station is complete,the cross-sectional streamline is continuous,and the quality of screw sleeve is good.The actual forging test shows that there are no forming defects throughout the whole process,which is consistent with the predicted result.The quality of screw sleeve is stable,and the productivity and efficiency are significantly improved,meeting the expected standards of the enterprise.