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针对某带轮轮毂带有锥度凸台的结构特点,对其凸台增厚展开冲锻成形工艺研究,制定出两道次镦粗成形方案。利用有限元分析软件Deform-2D分析了锥度凸台在预镦粗及终镦粗过程中的等效应变分布及成形载荷,并研究了凹模圆角及阻力墙对成形的影响规律。研究结果表明:在镦粗成形过程中,坯料在压板圆角处产生折叠及破裂的趋势较大,最大成形载荷为1000 kN左右,对压力机吨位要求较低;当凹模圆角半径R为10 mm时,成形结果良好,没有产生折叠缺陷;当阻力墙的斜角θ为45°时,阻力墙阻流效果最好。最终通过物理试验得到了合格的成形零件,验证了成形工艺及参数选择的可靠性。
Aiming at the structural characteristics of a pulley hub with taper bosses, the billet thickening of the bosses was developed for punching and forging forming process, and a two-stage upsetting scheme was developed. The finite element analysis software Deform-2D was used to analyze the equivalent strain distribution and the forming load of the tapered bosses during the process of pre-upsetting and final upsetting. The influence of the fillet and the resistance wall on the forming process was also studied. The results show that during the upsetting process, the billet tends to fold and rupture at the fillet radius, the maximum forming load is about 1000 kN, and the requirement on the tonnage of the press is low. When the radius R of the die is 10 mm, the forming result is good and no folding defects are produced. When the inclination angle θ of the resistance wall is 45 °, the blocking effect of the resistance wall is the best. In the end, the qualified shaped parts were obtained through physical experiment, which verified the reliability of the forming process and the parameter selection.