基于有限元分析的汽车十二角半轴螺母冷镦工艺开发与应用  

Development and application of cold upsetting process for automobile twelve corner half axle nut based on finite element analysis

作　　者：王晓伟[1] WANG Xiao-wei(College of Electromechanical and Antomotive Engineering,Puyang Vocational and Technical College,Puyang 457000,China)

机构地区：[1]濮阳职业技术学院机电与汽车工程学院,河南濮阳457000

出　　处：《塑性工程学报》2023年第7期62-70,共9页Journal of Plasticity Engineering

摘　　要：针对汽车十二角半轴螺母热镦成形工艺中存在的工序繁杂、生产效率低、产品性能差、材料利用率低和成本高等问题,设计了一种6工位自动化冷镦成形工艺对其进行替换。通过室温压缩试验建立了40Cr合金钢的Johson-Cook本构模型,同时,利用Deform-3D数值模拟软件完成了各工位的连续成形模拟,并根据螺母各阶段的金属流动规律、填充完整度、截面网格变形情况和断裂趋势等信息分析了冷镦成形工艺的可行性,基于载荷分析预测了成形力大小;然后根据分析结果和成形工艺完成了各工位模具的制作,并通过冷镦机进行了试模制件。结果表明,获得的十二角半轴螺母表面光洁,填充完整,无折叠和裂纹等缺陷,与模拟结果完全吻合,经测量检验,螺母各处尺寸均在公差范围内,符合使用要求,证实了冷镦工艺的可靠性,此冷镦工艺能够取代热镦工艺。Aiming at the problems of complicated process,low production efficiency,poor product performance,low material utilization rate and high cost during hot upsetting process of automobile twelve corner half axle nut,the six station automatic cold upsetting process was designed to replace it.The Johson-Cook constitutive model of 40Cr alloy steel was established through room temperature compression test.At the same time,the continuous forming simulation of each station was completed by Deform-3D numerical simulation software.The feasibility of cold upsetting forming process was analyzed according to the information of metal flow law,filling integrity,deformation of the section grid,fracture trend and other information for each station of the nut,and the size of the forming force was predicted based on load analysis.Then,according to the analysis results and forming process,the dies for each station were made,and the test parts were made through cold upsetting machine.The results show that the surface of the obtained twelve corner half axle nut is smooth and clean,the filling is complete,and there is no fold,crack and other defects,which is completely consistent with the simulation result.Through measurement and inspection,the dimensions of the nut are within the tolerance range,which meets the requirements of use.It confirms the reliability of cold upsetting process and this cold upsetting process can replace the hot upsetting process.

关 键 词：十二角半轴螺母 冷镦成形工艺 Johson-Cook本构模型 金属流动规律 成形力 

分 类 号：TG376.3[金属学及工艺—金属压力加工]