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针对矩形花键冷挤压成形中出现齿形充填不饱满和成形力过大的缺陷问题,以x1(坯料直径)、x2(坯料初始倒角)、x3(入模半角)为优化变量,采用响应面法结合有限元数值模拟对花键冷挤压成形工艺参数进行多目标优化。根据实验设计结果分别建立了两个目标函数的二阶响应面模型,方差分析结果表明,模型预测精度高并能够较好地描述两个目标函数关于设计变量的响应。在优化范围内得到矩形花键轴成形最优工艺参数为:x1=Ф48.5 mm,x2=20°,x3=15°。将优化后的工艺参数进行实际验证,结果表明:前端塌角量降至0.27 mm,最大成形力降至1300 k N。工艺试验证明了采用多目标优化得到的工艺参数可以获得合格的产品。
For rectangular spline cold extrusion forming tooth fillet filling is not full and forming force is too large defects, with x1 (billet diameter), x2 (billet initial chamfer), x3 (mold half angle) as the optimal variable, using Response Surface Methodology and Finite Element Numerical Simulation of Spline Cold Extrusion Process Parameters for Multi-Objective Optimization. The second-order response surface model of two objective functions is established respectively according to the experimental design results. The ANOVA results show that the model has high prediction accuracy and can well describe the response of the two objective functions to the design variables. The optimal process parameters for rectangular spline shaft forming in the optimization range are: x1 = Ф48.5 mm, x2 = 20 °, x3 = 15 °. The optimized process parameters were validated. The results showed that the amount of frontal collapse dropped to 0.27 mm and the maximum forming force decreased to 1300 kN. Process tests prove that the process parameters obtained by multi-objective optimization can obtain qualified products.