基于响应面法的球销终镦工艺优化

为获得矿用设备常用球销终镦成形最佳工艺参数,提高球销成形质量,基于塑性成形理论,进行简单的模具设计,利用有限元软件对球销终镦成形过程进行仿真。结合响应面法,选取HALF模圆角半径、下模圆角半径、冷镦速度以及摩擦因数作为试验变量,设计响应曲面试验,建立二次多项式响应面模型,研究各试验因素对成形载荷大小的影响程度,并以成形载荷最小为优化目标,通过方差及回归分析,获得最优参数组合。结果表明:当HALF模圆角半径为3 mm、下模圆角半径为0.5 mm、冷镦速度为23.8 mm/s、摩擦因数为1时成形载荷最小。最后通过实际工艺试验验证了仿真的可靠性,证明通过数值模拟及响应面法获得最佳参数的方法是切实可行的。

Optimization of Final Upsetting Process of Ball Pin Based on Response Surface Method

In order to obtain the best process parameters for the final upsetting of ball pin commonly used in mining equipment and improve the forming quality of ball pin,based on the plastic forming theory,a simple die design was carried out. The finite element software was used to simulate the final upsetting process of ball pin. Combined with response surface method,the fillet radius of HALF die, the fillet radius of lower die,cold upsetting speed and friction coefficient were selected as test variables to design the response curve in the face test,the quadratic polynomial response surface model was established to study the influence degree of various test factors on the forming load. Taking the minimum forming load as the optimization objective,the optimal parameter combination was obtained through variance and regression analysis. The results show that when the fillet radius of HALF die is 3 mm,the fillet radius of lower die is 0.5 mm,the cold heading speed is 23.8 mm/s,and the friction coefficient is 1,the forming load is the minimum. Finally,the reliability of the simulation was verified by the actual process test,which proves that the method of obtaining the best parameters by numerical simulation and response surface method is feasible.