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法兰面焊接螺母在实际冷镦成形中容易出现孔口折叠缺陷,采用有限元模拟分析与试验相结合的方法对缺陷进行了研究。首先结合现有设备能力及制造成本确定工艺方案;然后通过Deform-3D有限元软件对法兰面焊接螺母冷镦成形中的金属流动过程进行了动态模拟分析,得到缺陷产生的机理,并进一步对缺陷影响因素进行分析;对缺陷产生机理及关键影响因素进行了试验验证,在此基础上提出改进措施。结果表明,孔口折叠是在镦锻成形过程中,凹穴内孔圆柱面的金属流向法兰面,同时上面金属向下流动造成金属回流而成,严重时产生折叠缺陷;无法完全避免金属孔口折叠,但可通过控制成形工艺来减少折叠程度。
Flange welded nuts are prone to collapse of the orifice in the actual cold forging, and the defects are studied by means of the combination of finite element analysis and experiment. Firstly, the technological scheme is determined by combining the existing equipment capacity and manufacturing cost. Then, the dynamic simulation of the metal flow in the cold heading process of the flange nut is carried out by Deform-3D finite element software, and the mechanism of the defect generation is obtained. Defect factors were analyzed. The mechanism of the defect and the key influencing factors were verified by experiments. On this basis, the improvement measures were put forward. The results show that in the process of upsetting and forming, the metal in the inner surface of the hole flows into the flange surface, and the metal flows downwards to cause the metal to flow backwards. In severe cases, folding defects are generated; the metal aperture can not be completely avoided Folding, but can be controlled by the forming process to reduce the degree of folding.