基于正交试验的螺母冲裁成形模具磨损分析及参数优化

以某车用螺母冷镦冲裁模具为研究对象,基于Archard磨损理论采用有限元分析软件DEFORM-3D,对上冲头磨损进行模拟分析,结果表明:上冲头的磨损主要发生在受力较大的刃口区域。为使模具寿命尽可能地延长,设计了正交试验,以降低上冲头磨损量为目标,选取冲裁间隙、冲裁速度、上冲头表面硬度、摩擦系数作为因素,并采用极差和方差对结果进行分析,得出各因素对上冲头磨损量的影响程度依次为:冲裁速度>冲裁间隙>上冲头表面硬度>摩擦系数,并得出最优参数组合为:冲裁间隙为8%t、冲压速度为5 mm·s^-1、模具表面硬度为53 HRC、摩擦系数为0.14。上冲头最大磨损量由13.1×10^-6 mm减小为3.66×10^-6 mm,能够很好地指导企业的生产。

Wear analysis and parameter optimization in blanking forming for nut based on orthogonal experiment

Taking the blanking die of cold heading for vehicle-used nut as object,the wear of upper punch was simulated and analyzed by finite element analysis software DEFORM-3D based on Archard wear theory.The results shows that the wear of upper punch mainly occurs in cutting edge region with high loading in forming process.Therefore,in order to extend the life of die,the blanking gap,the blanking speed,the surface hardness of upper punch and the friction coefficient were selected as facters,and the orthogonal experiment was designed to reduce the wear of upper punch.Then,the results were analyzed by using range and variance.Finally,the sequence of influencing factors is blanking speed,blanking gap,surface hardness of punch,friction coefficient respectively.The optimal parameters were obtained as the blanking gap of 8%t,the blanking speed of 5 mm·s^-1,the surface hardness of upper punch of 53 HRC,the friction coefficient of 0.14.Thus,the maximum wear depth of upper punch is reduce from 13.1×10^-6 mm to 3.66×10^-6 mm,and it is a good guidance for practical production in enterprises.