Multi-station cold heading forming technology on complex vehicle sleeve based on finite element analysis
For the production situation of a complex vehicle sleeve with multiple processing steps,high cost and low output,the multi-sta-tion forming technology was attempted to be applied in its production,and two forming schemes for the sleeve were developed based on the plastic deformation methods and the plastic deformation capacity of the production materials.Then,the numerical simulation models were established respectively.Based on physical experiments,the constitutive model and damage fracture model of the sleeve material were es-tablished in Deform-3D,and the simulated forming of the sleeve was completed.Furthermore,based on the filling situation of the mold,metal flow and material damage degree,the feasibility for the two processes was comprehensively analyzed,and the data of equivalent stress and load of forming parts at each station of the two schemes were compared to obtain the reliable forming scheme.Finally,the form-ing mold was manufactured,and the multi-station forming experiment of sleeve was carried out.The results show that the sleeve obtained is fully formed,good quality,no scratches on the surface,smooth inner holes without burrs or other defects,which is highly consistent with the simulation results.Moreover,the size measurement results of the sleeve are also in line with the process requirements,which ver-ifies the accuracy of the process.
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