带法兰盘的阶梯轴冷镦挤成形工艺研究

为了研究法兰盘阶梯轴零件成形过程，确定其合理的工艺方案，课题组运用Deform 3D软件对带法兰盘阶梯轴零件镦挤过程进行数值模拟。通过模拟结果对初定工艺方案进行分析，确定了3步成形工艺，并对该工艺进行改进。基于正交试验对改进工艺进行优化，综合模具载荷、折叠角大小和分布及应力分布等因素，确定了最佳的工艺方案。结果表明：采用3步成形工艺时，对法兰盘进行2步镦粗成形，即采用挤压法兰盘1次镦粗 法兰盘2次镦粗成形工艺，该工艺可有效降低模具载荷、折叠角的角度和面积及零件应力；且当压力机工作速度为5 mm/s，法兰盘拐角处模具圆角半径为5 mm，摩擦因数为0.05时，工件成形质量较优。通过实际生产获得了表面质量良好的法兰盘阶梯轴零件。

Cold Upsetting Extrusion Process Analysis of Multi Diameter Shaft with Flange

In order to study the flange shaft parts forming process to determine the rational process, in this paper upsetting extruding process of multidiameter shaft with flange was simulated with the Deform 3D software.The initial process was analyzed by the simulation results to determine the three step forming process, and the process was improved. Based on the orthogonal experiment the optimal process scheme was determined by optimizing the process and mould load, size and distribution of folding angle,stress distribution and other factors, the best process scheme was determined.The results show that adopt the three steps of upsetting for flange, that is extrusion flange one times upsetting flange two times upsetting, the forming process can effectively reduce the mould load, angle and area of folding angle and stress of parts. When the working speed of the press is 5mm/s, mould corner is 5 mm, the friction coefficient is 0.05, the workpiece quality is excellent and obtain the multi diameter shaft parts with good surface quality in the actual production.