术文章细小管件之冷锻成形分析与模具设计.PDFVIP

技 術 文 章 細小管件之冷鍛成形分析與模具設計 Cold Forging Simulation and Die Design for a Small Tube Forming 余征諴、許進忠、毛建豐、陳彥宏 Cheng-Hsien Yu, Jinn-Jong Sheu, Chien-Feng Mao, Yan-Hong Chen 摘 要 細小圓形管件在成形過程中，需使用高細長比之沖頭，導致沖頭壽命不佳及成形精度不良等問題，本文 提出結合反向擠伸及縮管之製程，以建立細小圓形管件之冷鍛成形模具設計方法，使用有限元素分析，以評 估不同之反向擠伸預成形設計及不同縮管模具設計(含錐形模、曲線模及雙曲線模) ，探討不同設計組合對細 小圓形管件產品幾何尺寸精度之影響。由分析結果發現，不同反向擠伸預成形設計將影響細小圓形管件之最 終管壁厚度，而不同縮管模具設計則影響細小圓形管件成形缺陷，不良縮管模具設計可能導致內孔尺寸不佳 及成品表面刮傷等問題，本文出之較佳反向擠伸預成形及縮口模設計，可以得到良好產品及維持模具壽命。 關鍵字：細小管件，預成形設計，縮管模具設計，模具壽命，有限元素分析 Abstract Punch of high slender ratio used in the small tube forming causes the problems of poor tool life and bad accuracy. In this paper, an integrated backward tube extrusion and ironing process was proposed to obtain a feasible small tube forging die design. FEM method was adopted to predict the forming results of backward extrusion and ironing process (with conical die, curve die, and double curved die). Effects of the different design combination on the geometry accuracy were studied. The simulation results revealed that different backward extrusion designs have strong influence on the final tube wall thickness, and the different ironing process designs have strong influence on the occurrence of defects. Poor die designs resulted in the bad tube inner dimension and the surface scratching defect. The proposed better backward extrusion die design and ironing die design were capable of obtaining good product accuracy and tool life. Keywards: small tube, preform design, ironing die design, die life, FEM 料變形應變率變化說明，成功克服入出口的差距大 一、前 言 的應變率。Chitkara 等人[2] ，目的是預測不同設計 細小圓管產品是屬於精密微小製程，一般製程 心軸形狀的擠伸壓力，利用切片法和實驗來做比 是抽拉成形，但本產品的細小圓管產品的頭部有造 較，結果擠伸壓力很接近的。Ghaei 等人