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针对凸轮常见生产方法存在的材料利用率过低、产量低、生产周期长等问题,尝试了轧制成形工艺。基于DEFORM刚塑性有限元法建立了凸轮轧槽不变,只改变辊缝的多道次轧制过程的三维有限元模型。模拟分析总延伸系数不同时轧件的孔型充满度,确定出最佳轧制道次为2;分析坯料直径不同时轧件的孔型充满度及变形均匀性,确定出最佳坯料直径为Φ72 mm。在Ф160 mm×200 mm两辊轧机上验证了在最佳轧制道次和坯料直径下,40Cr凸轮的轧槽不变轧制成形工艺。实验得到轧件横截面组织分布与模拟应变分布规律一致,证明了模拟结果的准确性。
Aiming at the problems of low utilization rate of materials, low output and long production cycle of common production methods of cams, the rolling forming process was attempted. Based on the DEFORM rigid-plastic finite element method, a three-dimensional finite element model was established to change the multi-pass rolling process without change of cam groove. The full rolling degree of the rolling part is simulated and analyzed, and the optimal rolling pass is determined as 2. The fullness and deformation uniformity of the rolling part are analyzed when the billet diameter is different. The optimum billet diameter Φ72 mm. In the Ф160 mm × 200 mm two-roll mill verified the 40Cr cam groove rolling process at the optimal rolling pass and blank diameter. The experimental results show that the distribution of the cross section of the rolling stock is consistent with the distribution of simulated strain, which proves the accuracy of the simulation results.