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小型薄壁套管类零件,整体尺寸较小且内外结构复杂,加工方法的选择和成形工艺设计方面是生产该类零件的重点和难点。针对上述难点,采用适合中小型零件批量加工的多工位冷成形加工方法,并根据成形理论分析,初步设计出两种较合理的六工位冷成形方案,对成形过程采用Deform-3D软件数值模拟。得出先反挤压成形薄壁端的最大载荷为5.6×104N,远小于先镦粗成形凸缘的最大载荷;台阶深孔的成形采用杯-杯复合挤压,其损伤值远小于材料的临界损伤值。最终通过生产试验验证模拟结果的最佳工艺,且成形后小型薄壁套管的内部组织分布合理,无冷镦缺陷。
Small thin-walled casing parts, the overall size of small and complex internal and external structure, the choice of processing methods and forming process design is the production of such parts of the key and difficult. In view of the above difficulties, the cold forming process of multi-station for batch processing of small and medium-sized parts is adopted. According to the forming theory analysis, two more reasonable cold forming schemes of six stations are preliminarily designed. Deform-3D software is used for the forming process simulation. The maximum load of anti-extrusion thin-walled end is 5.6 × 104N, which is far less than the maximum load of upsetting flange. The forming of step deep hole is cup-cup compound extrusion, the damage value is far less than the material critical damage value. Finally, through the production test to verify the simulation results of the best technology, and after the formation of small thin-walled tube internal tissue distribution is reasonable, without cold heading defects.