柴油机喷射系统泵体精密挤压工艺

目的为了提高燃油喷射系统泵体的综合性能和制造效率,采用精密挤压来实现变量泵泵体的高效绿色制造。方法通过工艺设计,初步确定了锻件形状、分模形式和模具结构,采用有限元法对泵体精密挤压工艺进行仿真分析,研究了挤压成形时金属在型腔的流动规律,模具结构对挤压时的影响,以及锻件边角的充型情况。结果通过模拟仿真,对设计的挤压工艺进行了理论验证,坯料流动主要以充填法兰和外侧飞边的方向为主,外六角根部、法兰底部均充填完全,最终多余的金属流向模具间隙,没有出现紊流和涡流的现象。结论通过最终的工艺试制试验,验证了设计的工艺方案,精密挤压的变量泵泵体充型饱满,法兰顶部及根部六角形均充型完全,经机加工后成品尺寸稳定,满足产品的技术要求。

The Precision Extrusion Forming of the Pump Body Used for the Injection System of Diesel Engine

The work aims to improve the comprehensive performance and manufacturing efficiency of the pump body of the fuel injection system with precision extrusion, so as to achieve the highly-efficient and green manufacturing of the pump body. Through the process design, the forging shapes, form of die splitting and die structure were initially determined. By using the finite element method, the precision extrusion process was analyzed with simulation. Metal flow rule in the cavity, the influence of die structure on the extrusion and mold filling of forging edges were studied. The designed extrusion process was theoretically verified by analog simulation. Blank flow was mainly used to fill the flange and the outside flash. The outer hexagon corners and the bottom of the flange were filled completely. Finally, the excessive metal flowed to the die gap and no turbulence and vortex occurred. Through the final process trial-production test, the designed process design is verified, the variable pump body is fully filled, and the top of flange and the root of hexagon are filled completely. After machining, the dimension of finished products is stable and meeting the technical requirements.