基于有限元分析的车用复杂套管多工位冷镦成形技术  

Multi-station cold heading forming technology on complex vehicle sleeve based on finite element analysis

作　　者：杨锦林[1] 杨晓红 Yang Jinlin;Yang Xiaohong(School of Transportation Service and Management,Hebi Polytechnic,Hebi 458030,China;Hebi Institute of Engineering and Technology,Henan University of Technology,Hebi 458030,China)

机构地区：[1]鹤壁职业技术学院交通服务与管理学院,河南鹤壁458030 [2]河南理工大学鹤壁工程技术学院,河南鹤壁458030

出　　处：《锻压技术》2025年第1期48-58,共11页Forging & Stamping Technology

基　　金：河南省科技攻关项目(232102221023)。

摘　　要：针对某车用复杂套管加工工序多、成本高、产量低的生产现状,将多工位成形技术应用于其生产。围绕塑性变形手段和生产材料的塑性变形能力制定了套管的两套成形方案,并分别建立了数值仿真模型;基于物理试验在Deform-3D中建立了套管材料的本构模型及损伤断裂模型,完成了套管的模拟成形,并根据模具的填充情况、金属流动、材料损伤程度等全面分析了两套工艺的可实施性;比较了两方案各工位成形零件的等效应力及载荷等数据,得到了可靠的成形方案。最后,进行了成形模具的制造以及套管的多工位成形试验,得到的套管成形饱满,质量好,表面无刮痕,内孔光滑且无拉毛等缺陷,与仿真结果一致,且套管的尺寸检测结果也均符合工艺要求,验证了工艺的准确性。For the production situation of a complex vehicle sleeve with multiple processing steps,high cost and low output,the multi-station forming technology was attempted to be applied in its production,and two forming schemes for the sleeve were developed based on the plastic deformation methods and the plastic deformation capacity of the production materials.Then,the numerical simulation models were established respectively.Based on physical experiments,the constitutive model and damage fracture model of the sleeve material were established in Deform-3D,and the simulated forming of the sleeve was completed.Furthermore,based on the flling situation of the mold,metal flow and material damage degree,the feasibility for the two processes was comprehensively analyzed,and the data of equivalent stress and load of forming parts at each station of the two schemes were compared to obtain the reliable forming scheme.Finally,the forming mold was manufactured,and the multi-station forming experiment of sleeve was carried out.The results show that the sleeve obtained is fully formed,good quality,no scratches on the surface,smooth inner holes without burrs or other defects,which is highly consistent with the simulation results.Moreover,the size measurement results of the sleeve are also in line with the process requirements,which verifies the accuracy of the process.

关 键 词：套管 多工位成形技术 本构模型 损伤断裂模型 等效应力 载荷 

分 类 号：TG316.8[金属学及工艺—金属压力加工]