【摘要】：在精密鍛造技術(shù)中,溫冷復(fù)合成形工藝結(jié)合了溫鍛和冷鍛的優(yōu)點(diǎn),具有顯著的成形優(yōu)勢(shì),被廣泛應(yīng)用于機(jī)械制造行業(yè)中。中空薄壁類零件種類繁多,壁薄,結(jié)構(gòu)復(fù)雜,尺寸精度及力學(xué)性能要求較高,在汽車變速器系統(tǒng)、底盤系統(tǒng)及發(fā)動(dòng)機(jī)系統(tǒng)中需求量極大。目前此類零件多采用溫冷復(fù)合精密鍛擠工藝進(jìn)行生產(chǎn),但是在工藝設(shè)計(jì)的合理性、制造精度和成形質(zhì)量的控制方面還存在許多問題。因此,研究中空薄壁類零件的成形工藝特點(diǎn)并通過工藝改進(jìn)消除典型的成形缺陷,對(duì)此類零件生產(chǎn)質(zhì)量的提高具有重要的指導(dǎo)意義。本文根據(jù)零件形狀,將中空薄壁類結(jié)構(gòu)件分為杯類、杯桿類、帶法蘭及帶齒類。并分別對(duì)各類零件進(jìn)行結(jié)構(gòu)分析,提出了各類零件的主要成形工藝�？偨Y(jié)了中空薄壁類零件在實(shí)際生產(chǎn)中容易出現(xiàn)的質(zhì)量問題,對(duì)零件成形時(shí)的填充不足、尺寸精度低、組織不均勻和開裂問題進(jìn)行了研究,并提出了工藝解決方法。對(duì)齒類零件和杯類零件的填充問題進(jìn)行了研究分析,以法蘭外齒圈和薄壁鋼筒零件為例,為改善其成形質(zhì)量提出了工藝優(yōu)化方案。針對(duì)法蘭外齒圈生產(chǎn)中齒形填充不足和成形力大的問題,采用孔分流改進(jìn)工藝及溫?cái)D齒形工藝,提高了齒形填充性并降低了變形力,并獲得了溫?cái)D齒后最佳的齒形冷精整量。模擬結(jié)果表明采用兩種溫?cái)D齒方案成形后的鍛件齒形輪廓填充飽滿,且成形力低,不僅縮短了生產(chǎn)時(shí)長(zhǎng)也提高了成形質(zhì)量。針對(duì)目前薄壁鋼筒零件冷精整工序中產(chǎn)生的筒底間隙問題,在冷鍛前增加一道切削肩部斜角工序可以顯著降低間隙值。本文以某鋼筒為例對(duì)冷精整工序中的金屬流動(dòng)過程進(jìn)行了分析,獲得了筒底間隙值的變化規(guī)律,并提出了合理的肩部斜角取值范圍。通過對(duì)多組設(shè)計(jì)方案進(jìn)行模擬,獲得了肩部斜角和凹模入模半角對(duì)筒底間隙和筒底厚度的影響規(guī)律,確定了最優(yōu)的肩部斜角和凹模入模半角。最后對(duì)反擠凹模結(jié)構(gòu)進(jìn)行改進(jìn),直接反擠出肩部斜角,模擬結(jié)果表明此方案不僅可以省去機(jī)加工工序,而且最終鍛件的形狀和尺寸精度都符合生產(chǎn)要求。對(duì)成形過程中出現(xiàn)的裂紋問題進(jìn)行了研究。以蓄能器殼體零件為例,針對(duì)其冷成形中出現(xiàn)的開裂問題,提出了預(yù)成形設(shè)計(jì)方案和熱處理改進(jìn)方案來(lái)消除成形裂紋。其中對(duì)兩種預(yù)成形形狀進(jìn)行了模擬分析,確定了最優(yōu)的預(yù)成形結(jié)構(gòu);并將原成形方案中的去應(yīng)力退火工藝改為等溫退火工藝,結(jié)果表明顯著改善了冷成形中的鍛件組織消除了底部裂紋,且此方案已投入實(shí)際生產(chǎn)。
[Abstract]:In the precision forging technology, the warm and cold compound forming process combines the advantages of warm forging and cold forging, and has obvious forming advantages, and is widely used in the mechanical manufacturing industry. There are many kinds of hollow thin-walled parts, thin wall, complex structure, high dimensional precision and mechanical performance requirements, which is in great demand in automobile transmission system, chassis system and engine system. At present, this kind of parts is produced by temperature and cold compound precision forging and extrusion process, but there are still many problems in the aspects of the rationality of process design, the control of manufacturing precision and forming quality. Therefore, it is of great significance to study the forming process characteristics of hollow thin-walled parts and eliminate the typical forming defects through process improvement, which has an important guiding significance for the improvement of production quality of such parts. According to the shape of the parts, the hollow thin-walled structural parts are divided into cup type, cup rod type, flange and toothed type. The main forming process of each kind of parts is put forward by analyzing the structure of each kind of parts. The quality problems of hollow thin-walled parts in practical production are summarized. The problems of insufficient filling, low dimensional precision, uneven structure and cracking in forming are studied, and the technological solutions are put forward. The filling problem of tooth parts and cup parts is studied and analyzed. Taking the flange outer gear ring and thin-walled steel cylinder as examples, the process optimization scheme is put forward to improve the forming quality of tooth parts and cup parts. Aiming at the problems of insufficient filling and large forming force in the production of flange outer gear ring, the improved technology of split hole and warm extrusion was adopted to improve the filling property of tooth shape and reduce the deformation force, and the optimum cold finishing quantity of tooth profile after warm extrusion was obtained. The simulation results show that the profile of the forgings formed by two warm extrusion schemes is full and the forming force is low which not only shortens the production time but also improves the forming quality. In view of the gap problem in the cold finishing process of thin-walled steel cylinder parts, the gap value can be significantly reduced by adding a cutting shoulder bevel before cold forging. In this paper, taking a steel cylinder as an example, the metal flow process in the cold finishing process is analyzed, and the variation law of the gap value in the bottom of the cylinder is obtained, and a reasonable range of shoulder angle values is put forward. Through the simulation of many groups of design schemes, the effects of shoulder angle and die half angle on the bottom clearance and the thickness of the cylinder bottom are obtained, and the optimal shoulder angle and die entry half angle are determined. Finally, the structure of the reverse extrusion die is improved, and the angle of the shoulder is directly reversed. The simulation results show that this scheme can not only save the machining process, but also meet the requirements of the final forging shape and dimension accuracy. The crack problem in forming process is studied. Taking the accumulator shell as an example, the pre-forming design scheme and the heat treatment improvement scheme are proposed to eliminate the forming crack in view of the cracking problem in cold forming. Among them, two kinds of preformed shapes are simulated and analyzed, and the optimal preforming structure is determined. The results show that the structure of forging in cold forming has been greatly improved and the bottom crack has been eliminated, and the scheme has been put into practice.
【學(xué)位授予單位】：山東大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2017
【分類號(hào)】：TG316

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