滚针轴承薄壁外圈冲压成形工艺分析
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摘要
外圈冲压滚针轴承的薄壁外圈采用优质钢板经精密冲压而成,成形质量稳定,并且制造经济。但其成形工序多、材料弹塑性变形大,极易出现外圈挤压破裂和壁厚不均匀问题。采用有限元方法对某一型号滚针轴承外圈冲压成形的两道主工序过程进行数值模拟,研究其各个工序的成形规律,并分析模具冲压速度和圆弧过渡圆角大小对模具载荷和工件特征点应力变化的影响,为优化工艺参数选择提供依据。最后对毛坯落料和反拉伸阶段的成形件进行切样试验,并与仿真结果进行比对,两者具有很好的一致性,表明用本文建立的仿真分析方法来预测滚针轴承薄壁外圈多工序冲压质量的有效性,可为滚针轴承冲压工艺规范制定提供参考依据。
Thin-wall outer ring of the needle roller bearing is processed by precision stamping using high-quality steel, which has advantages as stable forming quality and manufacturing economy. However, it is easy to appear the problem of extrusion and fracture of the outer ring because of the multiple forming processes and large elastic and plastic deformation. In the paper, numerical simulation of finite element method is used for forming the outer ring of a needle roller bearing by two step process, study on the forming rule of each working procedure, and analysis the influence of die stamping speed and arc fillet size on reaction and feature points stress. These provide the basis for the selection and optimization of process parameters. Finally, the cut samples are compared with the simulation results, both are in good agreement. It shows the effectiveness to predict the thin-wall outer ring stamping quality using the established method, and can provide a reference for the needle bearing stamping process formulation.
Thin-wall outer ring of the needle roller bearing is processed by precision stamping using high-quality steel, which has advantages as stable forming quality and manufacturing economy. However, it is easy to appear the problem of extrusion and fracture of the outer ring because of the multiple forming processes and large elastic and plastic deformation. In the paper, numerical simulation of finite element method is used for forming the outer ring of a needle roller bearing by two step process, study on the forming rule of each working procedure, and analysis the influence of die stamping speed and arc fillet size on reaction and feature points stress. These provide the basis for the selection and optimization of process parameters. Finally, the cut samples are compared with the simulation results, both are in good agreement. It shows the effectiveness to predict the thin-wall outer ring stamping quality using the established method, and can provide a reference for the needle bearing stamping process formulation.
引文
[1]俞汉清,陈金德.金属塑性成型原理[M].机械工业出版社,2011.
[2]刘正兴,孙雁,包于浚,等.冲压外圈滚针轴承的部分优化设计[J].轴承,1992(2):2-18.
[3]黄志超,谢春辉,吕世亮.拉铆工艺过程数值模拟及实验[J].塑性工程学报,2014,10(7):1-4.
[4]M.C.Conor,M.John.2D and 3D finite element analysis of a three stage forging sequence[J].Materials Processing Technology,2002,12(7):3-7.
[5]X.H.Han,L.Hua,W.H.Zhuang.Process design and control in cold rotary forging of non-rotary gear parts[J].Journal of Materials Processing Technology,2014,11(4):2-6.
[6]朱景峰,李明滨,慕松,等.小型轴承套圈温挤压工艺及模具设计[J].轴承,2014(10):19-23.
[7]赵亮宇,郭俊卿,李冰,等.实体保持架等温挤压成形中损伤的数值模拟[J].轴承,2010(6):35-37,58.
[8]高新,赵春江,刘永锋,等.斜轧圆锥滚子轴承内圈毛坯的数值模拟及分析[J].轴承,2015(9):12-15,18.
[2]刘正兴,孙雁,包于浚,等.冲压外圈滚针轴承的部分优化设计[J].轴承,1992(2):2-18.
[3]黄志超,谢春辉,吕世亮.拉铆工艺过程数值模拟及实验[J].塑性工程学报,2014,10(7):1-4.
[4]M.C.Conor,M.John.2D and 3D finite element analysis of a three stage forging sequence[J].Materials Processing Technology,2002,12(7):3-7.
[5]X.H.Han,L.Hua,W.H.Zhuang.Process design and control in cold rotary forging of non-rotary gear parts[J].Journal of Materials Processing Technology,2014,11(4):2-6.
[6]朱景峰,李明滨,慕松,等.小型轴承套圈温挤压工艺及模具设计[J].轴承,2014(10):19-23.
[7]赵亮宇,郭俊卿,李冰,等.实体保持架等温挤压成形中损伤的数值模拟[J].轴承,2010(6):35-37,58.
[8]高新,赵春江,刘永锋,等.斜轧圆锥滚子轴承内圈毛坯的数值模拟及分析[J].轴承,2015(9):12-15,18.