高直臂小间距等厚板材零件步进式冲锻工艺

摘要/Abstract

摘要： 针对高直臂小间距、不能展平的等厚板材零件，提出了步进式冲锻成形工艺。该工艺先通过冲压成形零件的大间距两直臂，然后通过若干次弯曲工步来缩小两直臂间距直至达到目标值。每次弯曲成形后对工件弯曲变形部位需进行冷锻平整，选择合理的工步数是保证冷锻过程中不出现材料重叠、起皱或破裂等现象的关键。建立了流线型弯曲的数学模型，通过该模型得到每个弯曲工步极限图。采用数值模拟结合试验的方法获得了无工艺缺陷的产品，产品性能优良，生产效率高。该步进式冲锻工艺为成形高直臂小间距等厚金属板材零件提供了新途径。

关键词: 冲锻成形, 等厚, 步进式, 弯曲, 直臂

Abstract: Stepping press forging(SPF) process was proposed to form parts with high straight arms and small spacing, which could not be formed by normal stamping because the interferes would happen when the straight arms were expanded before stamping. Parts with large space straight arms were formed by stamping initially and then by using several bending steps to narrow the distance between the two straight arms to the target value. Cold forging should be used after every bending step to flat the bending area and it was important to select the reasonable stepping coefficients to avoid the overlap, wrinkling and cracking during cold forging. Bending limit diagrams for every bending step were obtained based on the mathematical model of streamline bending. Numerical simulations together with experiments were used to determine the stepping coefficients with no process defects. The SPF process is a new way to form such parts which have excellent performance and high productivity.

Key words: press forging, uniform thickness, stepping, bending, straight arm

中图分类号:

TG386

王可胜, 韩豫. 高直臂小间距等厚板材零件步进式冲锻工艺[J]. 中国机械工程.

Wang Kesheng, Han Yu. Stepping Press Forging Process for Uniform Thickness Parts of Sheet Metal with High Straight Arm and Small Spacing[J]. China Mechanical Engineering.

参考文献

[1]Jin Junsong，Xia Juchen，Wang Xinyun，et al. Die Design for Cold Precision Forging of Bevel Gear Based on Finite Element Method[J]. Journal of Central South University of Technology，2009，16（4）：546-551.

[2]Sun Cheng，Zhang Shihong，Tang Weidong，et al. Press Forging of Magnesium-alloy Notebook Case with Complex Geometry[J]. Materials and Manufacture Processes，2010，25 (7)：534-538.

[3]Zhao Zhen，Zhuang Xincun，Xie Xiaolong. An Improved Ductile Fracture Criterion for Fine-blanking Process [J]. Journal of Shanghai Jiaotong University，2008，13 (6)：702-706.

[4]Tan C J，Mori K，Abe Y. Forming of Tailor Blanks Having Local Thickening for Control of Wall Thickness of Stamped Products[J]. Journal of Materials Processing Technology，2008，202 (1/3)：443-449.

[5]Sheng Z Q，Shivpuri R. A Hybrid Process for Forming Thin-walled Magnesium Parts[J]. Journal of Materials Processing Technology，2006，428 (1/2)：180-187.

[6]王新云，欧阳坤，夏巨谌，等. 冲锻成形过程弯曲增厚工艺的有限元分析[J]. 锻压技术，2009，34 (4)：73-78.

Wang Xinyun，Ouyang Kun，Xia Juchen，et al. FEM Analysis of Drawing-thickening Technology in Stamping-forging Hybrid Process[J]. Forging & Stamping Technology，2009，34 (4)：73-78.

[7]王新云，夏巨谌，陈志明，等. 板冲锻成形新工艺及其在轿车飞轮盘加工中的应用[J]. 塑性工程学报，2008，15 (4)：180-184.

Wang Xinyun，Xia Juchen，Chen Zhiming，et al. Application of a New Sheet Stamping-forging Hybrid Technology in the Forming of Flying Wheel Panel of Car[J].Journal of Plasticity Engineering，2008，15 (4)：180-184.

[8]Wang Z G，Yoshikawa Y，Osakada K. A New Forming Method of Solid Bosses on a Cup Made by Deep Drawing[J].CIRP Annals-Manufacturing Technology，2013, 62 (1)：291-294.

[9]张士宏，周丽新，王忠堂. 板材零件局部体积成形技术研究[J]. 塑性工程学报，2008，15(2)：31-36.

Zhang Shihong，Zhou Lixin，Wang Zhongtang. Research on Local Bulk Forming of Sheet Metal Parts[J]. Journal of Plasticity Engineering，2008，15(2)：31-36.

[10]Zhang Shihong，Zhang Gang，Xu Yongchao，et al. Press Forging of Magnesium Alloy AZ31 Sheets[J]. Materials Science Forum，2007，539/543：1753-1758.

[11]Chen F K，Huang T B，Wang S J. A Study of Flow-through Phenomenon in the Press Forging of Magnesium-alloy Sheets[J].International Journal of Advanced Manufacturing Technology，2007,187/188：770-774.

[12]Chen F K，Huang T B，Chen S G. Embossment Formation in Press Forging of AZ31 Magnesium-alloy Sheets[J]. International Journal of Advanced Manufacturing Technology，2007，32 (32)：272-279.

[13]魏春雷. 冲压工艺与模具设计[M]. 北京：北京理工大学出版社，2007.

[1]	段永川;乔海棣;张芳芳;刘煜;杨柳;官英平. 屈服强度在线识别的分散性分析与精度验证[J]. 中国机械工程, 2020, 31(23): 2864-2873.
[2]	陈光耀, 李恒, 贺子芮, 马俊, 李光俊, 付颖. [成形过程的数据挖掘与深度学习方法]基于机器学习的管材弯曲回弹有效预测与补偿[J]. 中国机械工程, 2020, 31(22): 2745-2752.
[3]	徐勇, 李明, 夏亮亮, 张士宏, . [材料绿色成形技术]异形排气管多向局部加载液力成形工艺[J]. 中国机械工程, 2020, 31(22): 2763-2771.
[4]	汪泉；陈晓田；胡梦杰；曾利磊. 基于气动性能与刚度特性的风力机翼型优化设计[J]. 中国机械工程, 2020, 31(19): 2283-2289.
[5]	魏云波;赵丹阳;王敏杰;李红霞. 高径向支撑性可生物降解聚合物血管支架结构设计与力学性能分析[J]. 中国机械工程, 2020, 31(09): 1098-1107,1130.
[6]	范需;戴宁;王宏涛;丁龙伟;谢绍辉. 气动网格软体驱动器弯曲变形预测方法[J]. 中国机械工程, 2020, 31(09): 1108-1114.
[7]	林棻1；唐洁1；赵又群1；李剑垒1；臧利国2；陈宇珂1. 基于修正L-P模型的轮毂轴承载荷分布与弯曲疲劳寿命分析[J]. 中国机械工程, 2020, 31(08): 898-906.
[8]	王兴东1;杨雅伦1;孔建益1;施毅2. 基于区域优化的等厚对接焊缝图像二值化方法[J]. 中国机械工程, 2019, 30(14): 1756-1763.
[9]	李斌斌1,2;赵友坤1;刘杰1. 腹板-翼缘搭接连接结构钉载分配特性研究[J]. 中国机械工程, 2019, 30(09): 1041-1048.
[10]	张运军1;陈天赋1;杨杰1;黄明伟1;夏巨谌2;邓磊2;金俊松2. 房车转向节整体模锻关键技术与模具装置研发[J]. 中国机械工程, 2018, 29(17): 2125-2130.
[11]	马瑞1,2;王春鸽3;赵军1,2;翟瑞雪1,2. 平面变形回弹迭代补偿的收敛准则及应用[J]. 中国机械工程, 2018, 29(14): 1696-1703.
[12]	汤朋朋1; 温雯1;黄永安2;刘谦1. 弯曲半径对柔性电子器件层间分离的影响[J]. 中国机械工程, 2017, 28(19): 2354-2359.
[13]	王长科, 阳光武, 朱涛, 于金朋. 车体设计参数对车体垂向弯曲振动频率的灵敏度分析[J]. 中国机械工程, 2016, 27(16): 2267-2271.
[14]	鲁世强, 方军, 唐金星, 王克鲁. 不同模具组合对0Cr21Ni6Mn9N不锈钢管数控弯曲成形质量的影响[J]. 中国机械工程, 2016, 27(12): 1673-1678.
[15]	方军, 鲁世强, 王克鲁, 姚正军. 工艺参数对21-6-9高强不锈钢管数控弯曲壁厚减薄影响的显著性分析[J]. 中国机械工程, 2015, 26(9): 1233-1238,1277.