影响汽车冲压模具寿命的因素分析

影响汽车冲压模具寿命的因素很多,本文主要通过对模具结构、材料、使用及保养来分析模具寿命,并且提出有效提高冲压模具寿命的措施。     

温挤压模具设计的新方法

为了提高温挤压模具在高温高压下使用的寿命,从模具材料的选用、模具热处理方法到模具的加工等方面进行了分析,提出了延长模具寿命的新方法.温挤压技术发展很快,影响模具寿命的因素很多,经多年的研究与探讨发现,只要针对模具结构设计、模具材料、模具热处理、模具机械加工和模具润滑等主要因素根据具体情况正确选择和采用适当的措施,温挤压模具的寿命将会得到成倍提高.对使用这类模具的企业提供参考.     

提高模具寿命的途径

模具是生产中的一种重要的工艺装备,一般说来,模具制造精度要求高、制造周期长、材料贵重、造价较高,如果选材、设计、制造、使用不当,将会大大缩短模具的使用寿命,造成很大浪费。因此,为了保证生产的顺利进行、降低生产成本,提高模具寿命就显得十分重要。影响模具寿命的因素是多方面的,因而,提高模具寿命电应从各方面着手。本刊现发表几篇有关提高模具寿命的文章,从模具的选材、设计、制造工艺到安装使用等几方面提出了提高模具寿命的途径,可供参考。望读者结合本单位情况摸索出具体经验;把模具寿命提高到一个新水平。     

提高模具寿命的几条措施

从模具锻坯质量、模具制造工艺、热处理工艺等方面分析了影响模具寿命的因素,提出了提高模具寿命的措施.     

基于单片机的模具寿命管理系统设计北大核心

模具寿命往往直接关系到产品生产加工的效率、质量和成本,传统的人工检测方法无法准确检测模具失效而导致产品合格率降低。为了提高模具寿命管理的有效性,设计了一种基于单片机的模具寿命管理系统,通过模次计数实现模具寿命管理的准确性。该装置主要采用STM32L151、ATRF212-ZU、LED显示器、蜂鸣器等元器件,可实现模具动态过程的自动检测与数据交互,并开发相应的系统进行管理统计。通过实际操作与调试,装置可准确记录模具模次,实现模具寿命的检测与管理,满足实际使用要求。     

基于单片机的模具寿命管理系统设计

模具寿命往往直接关系到产品生产加工的效率、质量和成本,传统的人工检测方法无法准确检测模具失效而导致产品合格率降低。为了提高模具寿命管理的有效性,设计了一种基于单片机的模具寿命管理系统,通过模次计数实现模具寿命管理的准确性。该装置主要采用STM32L151、ATRF212-ZU、LED显示器、蜂鸣器等元器件,可实现模具动态过程的自动检测与数据交互,并开发相应的系统进行管理统计。通过实际操作与调试,装置可准确记录模具模次,实现模具寿命的检测与管理,满足实际使用要求。     

影响不锈钢级进模寿命的因素及对策

根据不锈钢级进模的特点,从冲压件工艺性,模具结构,模具材料,模具的热处理工艺、模具加工工艺,正确使用、维护和保养模具等六个方面,探讨了影响不锈钢级进模寿命的因素以及提高模具寿命的有效途径。     

提高花键轴冷挤压模具寿命研究

防止模具早期失效,提高模具寿命是研究冷挤压工艺在花键轴加工中应用的重要环节。分析花键轴冷挤压模具的几种常见失效形式及其特点,从模具材料选择、模具结构设计以及坯料的热处理等方面提出了提高模具寿命的措施。     

基于局部应力应变法的弧齿锥齿轮锻造模具寿命预测

模具寿命是影响弧齿锥齿轮锻造成本的主要因素之一。采用弹塑性有限元模型,对弧齿锥齿轮热锻成形的模具应力分布进行了模拟仿真,基于局部应力应变法,从模具的预热温度、齿模齿顶的过渡圆弧半径以及锻造成形速度等工艺因素计算模具的应力应变分布,分析各工艺因素对模具寿命的影响规律。模拟结果表明,热锻成形的弧齿锥齿轮的模具失效形式,主要为齿模的齿顶和齿根处应力集中引起的断裂。对于齿模的齿顶位置来说,三种工艺参数的变化与齿模疲劳寿命成正比。对于齿模的齿根位置来说,工艺参数的变化与模具寿命成反比。提出的模具寿命预测方法为批量化生产中优化模具结构和预测模具寿命提供了技术参考。     

提高热锻模具寿命的有效途径

提高热锻模具寿命是降低锻件生产成本的重要途径。本文从锻模材料选择、锻模设计、锻模热处理以及模具的使用与维护等方面,分析提出了提高热锻模具寿命的有效途径,对提高锻模寿命和产品质量以及降低生产成本具有指导意义。     

Cover die service life improvement by biomimetic laser-remelting process and CAE simulation

Die service life improvement is an important problem in high-pressure die-casting industry. As many factors affecting the service life, die service life improvement is a systematic project. In this paper, a cover die-casting die was investigated in order to increase its life time. Different die materials, computer-aided engineering (CAE) analysis, biomimetic laser-remelting process, and die structure optimization are adopted in order to enhance its performance. The die service lives are traced for dies of different die materials (H13 and SKD61). The die service lives are compared for dies with/without structure optimization with the help of CAE simulation. The application shows that CAE simulation is a useful tool for die structure optimization. Experiment result on SKD61 die steel after laser-remelting process shows that biomimetic laser-remelting process provides desirable microstructural and microhardness changes in biomimetic units, which induces the intensified particles for improving the service life.     

Performance enhancements of high-pressure die-casting die processed by biomimetic laser-remelting process

Die service life improvement is an important problem in high-pressure die-casting industry. Experiment results on die steel shows that biomimetic laser-remelting process provides a promising method to improve the service life of die-casting die. A casting with uneven wall thickness was selected and problems existing in die-casting production were analyzed. The corresponding die-casting die was processed by biomimetic laser-remelting process. The application result indicates that the service life of the die processed by biomimetic laser-remelting process has been increased from 12,000 to 28,000 shots, which is more than twice that of no processed one under real high-pressure die-casting conditions. The application of laser-remelting process provides desirable micro-structural changes in biomimetic units, which induces the intensified particles effect for improving the service life.     

热加工工艺对锻模寿命的影响

分析研究了从冶炼、锻造及热处理等锻模热加工的各工序对锻模使用寿命的影响,并制定了预防锻模早期失效和提高锻模使用寿命的措施。重点阐述了模坯锻造过程中应注意的工艺技巧及方法,提出了针对热锻模具采用不同的热处理工艺和表面强化处理方法。     

冷冲压模具材料的合理选择

模具的使用寿命主要受材料和热处理工艺的影响.分析了模具材料性能、种类及特性,从而合理选择模具材料,提高模具寿命.降低成本.     

基于修正Archard理论的螺旋锥齿轮锻造模具寿命预测

基于修正的Archard理论,采用弹塑性有限元模型对螺旋锥齿轮热锻成形的模具磨损进行了模拟仿真,分别从齿模齿顶的过渡圆弧半径、模具热处理硬度、模具的预热温度以及锻造成形速度四个方面对模具易磨损位置的磨损量进行计算,采用正交试验优化设计方法分析各工艺因素对模具寿命的影响规律,确定最优的工艺参数进行锻造试验。试验结果表明,使用提出的预测模具寿命的方法估算的模具寿命与试验结论具有较好的一致性。     

Die fatigue life design and assessment via CAE simulation

In die design process, the design and prediction of die fatigue life is a non-trivial issue. Many factors in die life cycle from design, fabrication to service all affect die life. The die life in cold forging processes is basically determined by die fatigue failure. The design and assessment of die fatigue life needs to consider all the affecting factors including die structure and component design, materials selection and properties configuration, die fabrication and service conditions. Currently, there is no efficient approach to providing complete solutions by considering all of these factors. CAE simulation technology, however, presents a promising approach to addressing the issue. In this paper, a simulation-based approach for die life design and assessment is presented. The approach employs both stress-life and strain-life fatigue analysis methods to conduct the die fatigue life design and analysis based on the stress and strain revealed by CAE simulation. As the die stress and strain in forming process vary dynamically, the integrated simulation of forming process and die deformation is conducted in such a way that the dynamic die stress and strain can be identified and determined. To implement this idea, a realization framework is orchestrated and the processes and procedure under the framework are succinctly articulated. The implementation with case studies is finally used to test and verify the validity, robustness, and efficiency of the developed approach. The approach is proven to be able to provide satisfactory solutions for die life design and assessment in the early stage of die design.     

Estimation of die service life for a die cooling method in a hot forging process

Dies may have to be replaced for a number of reasons, such as changes in dimensions due to wear or plastic deformation, deterioration of the surface finish, breakdown of lubrication, and cracking or breakage. In this paper, die cooling methods are suggested to improve die service life with regards to wear and plastic deformation in a hot forging process. The yield strength of die decreases at higher temperatures and is dependent on hardness. Also, to evaluate die life due to wear, a modified Archard’s wear model has been proposed by considering the thermal softening of die expressed in terms of the main tempering curve. This paper describes the effects of die cooling methods such as cooling hole and direct spray cooling on the life of finisher die during the hot forging of an automobile part. It is shown that the cooling hole method during hot forging is necessary for an effective die service life to be obtained.     

汽车同步齿环凹模失效分析

分析了两种典型汽车同步齿环失效模具的化学成分、断口形貌及显微组织,同时研究了模具表层温度对其失效形式的影响.结果表明:化学成分不合格、电火花加工缺陷及应力集中是模具早期失效的主要原因;在锻造过程中模具表层温度升高对模具的变形失效有非常重要的影响;最后针对生产实际提出了提高模具使用寿命的方法,并取得了一定的效果.     

冲模寿命影响因素的分析研究

采用图表方式分析了影响冲模寿命的各种因素,提出了改善措施,提高了冲模的寿命.     

基于ANSYS的拉丝模几何参数数值优化

拉丝模几何参数是影响其使用寿命的关键因素之一.本文应用有限元方法对拉丝模的强度进行分析,得到了不同圆锥高度的摩擦应力、米塞斯应力和应变值.根据摩擦应力、米塞斯应力和应变的变化曲线,寻找到拉丝模最佳几何参数,以延长拉丝模的使用寿命.