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针对某球头销尺寸规格较大、球头至杆部过渡区带有反锥轴颈和选用中高强度材料等特点,对其冷挤压成形工艺进行了研究。首先,对成形工艺和模具结构进行了分析,制定了闭式镦挤、分离对开式两步成形的冷挤压工艺方案;然后利用刚塑性有限元方法对冷挤压成形过程进行模拟,并通过速度场、等效应力应变以及载荷-行程曲线的分析,获得了在一定条件下金属坯料在模具型腔内的塑性流动规律,预测了成形过程中可能出现的缺陷。结果表明,提出的冷挤压工艺方案和模具能够满足零件生产要求,拓宽了冷挤压成形应用范围。
Aiming at the big size of a ball stud, the transition zone from the ball head to the shaft has the features of anti-taper journal and medium-high strength material, and the cold extrusion forming process is studied. Firstly, the forming process and the structure of the mold were analyzed, and the cold extrusion process scheme of closed upset extrusion and split two-step split-off was established. Then the cold-plastic forming process was simulated by the rigid-plastic finite element method Through the analysis of velocity field, equivalent stress and strain and load-stroke curve, the plastic flow rule of metal blank in the mold cavity under certain conditions was obtained and the possible defects in the forming process were predicted. The results show that the proposed cold extrusion process program and die to meet the production requirements of parts and broaden the range of cold extrusion applications.