模具技术2018.No.2
文章编号：1001-4934(2018)02-0001-07
1
车用齿轮轴冷挤压成形模拟及反挤压工艺参数优化
曹守亮，张莹，陈莹莹，姬忠超，龚红英，廖泽震
(1.上海工程技术大学材料工程学院，上海201620； 2.上海东芙格尔冷锻制造有限公司，上海201100）
摘要：针对车用齿轮轴制定了冷挤压成形工艺方案，并对其进行了相应的正、反挤压模具设计。利用Deform-3D进行有限元仿真模拟，对成形件进行等效应变、等效应力、损伤和载荷一行程曲线分析。选取凸模速度、摩擦因数以及凸模锥角3种工艺参数进行正交试验及工艺优化，通过正交试验的方差分析得出摩擦因数对齿轮轴反挤压载荷大小具有显著影响，并得到各参数对成形载荷的影响顺序为：摩擦因数>凸模锥角>凸模速度。最终得到的最优反挤压工艺参数为：凸模速度为25mm/s，摩擦因数为0.10和凸模锥角为25°。优化后反挤压的最大载荷由原来的2.15×10*kN减小到 1.01×104kN.降低了53个百分点。
关键词：齿轮轴；冷挤压：数值模拟；正交试验；工艺优化
中图分类号：TG376
文献标识码：A
Numerical simulation and process parameters optimization of backward extrusion
for vehicle gear shaft
CAO Shou-liang , ZHANG Ying , CHEN Ying-ying, JI Zhong-chao , GONG Hong-ying , LIAO Ze-huar Abstract: A cold extrusion process was developed for the gear shaft of the vehicle and the corre -sponding forward and backward extrusion die design were carried out . The analysis of equivalent strain, equivalent stress, damage and load-stroke curve of the forming part were analyzed by the finite element simulation based on Deform-3D.The effects of punch velocity ,friction coefficient and punch angle were selected for orthogonal experiment and process optimization .The variance a nalysis of the orthogonal test shows that the friction coefficient has a significant effect on the back -ward extruding load of the gear shaft and the order of influence of each parameter on the forming load is as follows : friction coefficient>punch angle>punch velocity . The optimal parameters of backward extrusion process were obtained finally : punch speed is 25 mm/s, friction coefficient is O.10 and punch angle is 25°. The maximum load of the optimized backward extrusion is reduced from2.15X10*kNto1.01X10*kN,whichdrops53%.
收稿日期：2017-09-15
基金项目：上海市大学生创新训练项目（cs1505001），上海高校青年教师培养资助计划项目
(ZZGCD15035），上海工程技术大学科研启动基金项目（校启2015-06），上海工程技术大学产学研合作重大项目（(17)CL-003）。
作者简介：曹守亮（1995一），男，学士。
通信作者方恭数（1980—），女，博士，讲师。