针对变速箱多台阶轴类件镦粗工序难度大的问题,提出了镦粗聚料—冷镦的工艺方案。运用有限元分析软件Deform-3D对轴类零件的冷镦成形过程进行了数值模拟,分析了填充不满造成成形力大的原因。研究了聚料直径D和聚料锥角α对成形质量及成形力的影响,确定了最佳D和α值。工艺试验表明,该方案成形质量好且成形力小。数值模拟结果对实际生产有指导意义。 In view of the difficulty of upsetting multi-stage shaft gearboxes, a process scheme of upsetting polymer-cold heading is proposed. The finite element analysis software Deform-3D was used to simulate the cold heading process of shaft parts, and the reasons for the large forming force were analyzed. The effects of the diameter of the polymer D and the angle α of the polymer on the forming quality and the forming force were studied, and the optimum D and α values ​​were determined. Process tests show that the program forming good quality and small forming force. The numerical simulation results have guiding significance to actual production.