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针对某型号多台阶轴头形状尺寸及冷精锻工艺特点,采取挤压、镦粗、缩径等不同工艺在工序内结合应用的方法,制定了多台阶轴头短流程冷精锻成形工艺。通过数值模拟和实验研究相结合的方法,对所制定的工艺进行分析研究,最终获得了两道工序成形8个台阶尺寸的多台阶轴头短流程冷精锻成形工艺,并在实验过程中采用了高分子润滑剂,进一步缩短了从下料到最终成形的整个工艺流程。结果表明:通过合理分配各工序变形量、工序内多种冷锻工艺结合应用的方法,可有效减少台阶轴冷精锻成形工序总数,实现在普通压力机上的高效率生产;Deform-3D模拟软件对工艺的模拟结果与实验结果相一致,说明有限元模拟对成形效果、压力大小的预测是可行的。
Aiming at the shape and size of multi-step shaft head and the characteristics of cold forging process of a certain model, cold forging process with multi-step shaft head short flow was developed by the combination of different processes such as extrusion, upsetting and shrinking. Through the combination of numerical simulation and experimental research, the developed process was analyzed and studied, and finally the cold forging process of multi-step shaft head with short steps of 8 steps was formed by two steps. In the experiment, The polymer lubricant to further shorten the whole process from the expected to the final shape. The results show that the total number of cold forging forming steps can be effectively reduced by reasonably distributing the amount of deformation of each process and the combination of various cold forging processes in the process so as to realize high efficiency production on a common press. Deform-3D simulation software The simulation results of the process are consistent with the experimental results, which shows that FEM simulation is feasible to predict the forming effect and pressure.