航空电机薄壁异形孔零件刷盒冷挤压成形工艺  

Cold extrusion forming process for brush box of thin-walled part with special-shaped hole in aviation motor

作　　者：袁玉红[1] 刘詹 伍太宾[2] 金俊松[3] Yuan Yuhong;Liu Zhan;Wu Taibin;Jin Junsong(School of Mechanical and Electrical Engineering,Guizhou Normal University,Guiyang 550025,China;School of Materials Science and Engineering,Chongqing University of Arts and Sciences,Yongchuan 402160,China;School of Materials Science and Engineering,Huazhong University of Science and Technology,Wuhan 430074,China)

机构地区：[1]贵州师范大学机械与电气工程学院,贵州贵阳550025 [2]重庆文理学院材料科学与工程学院,重庆永川402160 [3]华中科技大学材料科学与工程学院,湖北武汉430074

出　　处：《锻压技术》2025年第2期85-93,共9页Forging & Stamping Technology

基　　金：贵州省自然科学基金资助项目(黔科合基础[2020]1Z050)。

摘　　要：针对航空直流电机刷盒中薄壁异形孔壁厚不均、对称度高等特点,设计了冷挤压成形工艺方案。运用模拟分析软件Deform-3D对异形孔复合挤压过程进行仿真,分析了变形金属流动特点、3个变形区的最大主应力状态及损伤值。结合正交实验,以预制坯孔径和凸模前端直径为影响因素,建立了2因素3水平正交实验方案,分析了不同工艺参数组合下的异形孔成形情况,极差分析结果表明:预制坯孔直径为Φ5.5 mm、凸模前端直径为Φ5.0 mm为最优工艺参数组合,此组合下圆孔与长方孔过渡圆弧面损伤值最小,薄壁孔产生裂纹倾向最小。在液压机上进行工艺实验验证,挤压件成形质量良好,达到设计要求。For the characteristics of uneven wall thickness and high symmetry of thin-walled and special-shaped hole in the brush box of aviation DC motors,the cold extrusion process scheme was designed.Then,the composite extrusion process of special-shaped holes was simulated by the simulation analysis software Deform-3D,and the flow characteristics of deformed metal and the maximum principal stress states in the three deformation zones as well as the damage values were analyzed.Furthermore,combined with orthogonal experiment,taking the diameters of preformed blank hole and front end of punch as the influence factors,the orthogonal experiment scheme of two factors and three levels was designed,and the forming of special-shaped hole was analyzed.The results of range analysis show that the optimal process parameter combination is that the diameter of preformed blank hole isΦ5.5 mm and the front end diameter of punch isΦ5.0 mm,under this condition,the damage value of transition circular arc surface between circular and rectangular holes is the smallest,and the cracking tendency of thin-walled hole is the smallest.The process experiments are conducted on the hydraulic press,and the forming quality of extrusion part is good and meets the design requirements.

关 键 词：薄壁异形孔 冷挤压 金属流动特点 最大主应力 损伤值 

分 类 号：TG376.3[金属学及工艺—金属压力加工]