实际生产发现,一次挤压成形的六角接头出现严重的波浪状裂纹,导致零件报废。基于Deform-3D软件对六角接头的冷挤压工艺进行模拟。结果表明:由于零件内孔直径和六角接头内切圆直径近似相等,一次成形相当于冲孔过程;另外,当金属由圆柱体流向六棱柱时,形状改变导致金属流动不均匀。这两个因素使得零件的六角形表面出现波浪状裂纹。研究表明,增加中间工序,即先正挤压得到六棱柱,再反挤压得到内孔,且数值模拟和实际生产均得到合格零件。 The actual production found that an extrusion of hexagonal joints serious wavy crack, resulting in scrap parts. The cold extrusion process of hexagonal joint was simulated based on Deform-3D software. The results show that the forming process is equivalent to the punching process because the hole diameter of the part and the inscribed circle diameter of the hexagonal joint are approximately equal. In addition, when the metal flows from the cylinder to the hexagonal prism, the shape changes cause the metal to flow unevenly. These two factors make wavy cracks on the hexagonal part of the part. The research shows that the increase of the intermediate process, that is, the first squeeze to obtain a hexagonal prism, and then squeeze back to get the inner hole, and numerical simulation and actual production have been qualified parts.