基于有限元分析的球形垫片冷锻精密成形工艺研究

Research on the Precision Forming Process of Spherical Washers in Cold Forging Based on Finite Element Analysis

摘要:

随着交通运输和航空航天等行业的发展，市场对紧固件的质量和可靠性要求不断提高。球形垫片作为关键紧固件，广泛应用于机械、管道和阀门等设备中，其质量直接关系到设备的安全性和可靠性。冷锻工艺凭借常温成形的显著特性，成为生产球形垫片的理想工艺。通过设计和优化冷锻工艺，并结合有限元模拟技术，解决生产中的潜在问题，从而提高生产效率、降低成本，保证产品质量。通过Deform-3D有限元软件对球形垫片的冷锻成形过程进行模拟分析，发现了金属流动不均、充填不良、表面开裂等潜在问题，为解决这些问题，设计了预锻和终锻两步冷锻形成工艺。预锻阶段形成类筒形结构，为复杂的内花键区域提供金属积聚，确保后续成形顺利进行；终锻阶段通过精确的模具设计控制金属流向，确保锻件的端部和花键的精准成形。模拟结果表明，两步冷锻工艺能够使金属均匀填充模具型腔，避免飞边过多产生，并有效抑制了充不满和折叠等缺陷。该工艺设计显著提高了球形垫片的成形精度，减少了开模和试模费用，降低了研发成本，为实际生产提供了可靠的数据支持。在试制过程中，采用与模拟一致的工艺参数，最终生产出的球形垫片零件质量良好、表面光洁、无裂纹及尺寸精度符合要求，验证了该工艺方案的可行性。基于有限元分析的冷锻成形工艺为球形垫片的高质量生产提供了一种有效的冷锻工艺方案，同时通过有限元模拟技术优化了成形过程，降低了生产成本和研发风险，为其他复杂结构零件的制造提供了重要参考。

Abstract:

With the development of industries such as transportation and aerospace， the demand for higher quality and reliability of fasteners has increased. Spherical washers， as key fasteners， are widely used in machinery， pipelines， and valve equipment， where their quality directly affects the safety and reliability of the equipment. Cold forging， due to its room temperature forming characteristics， has become the ideal method for producing spherical washers. This paper aims to design and optimize the cold forging process by using finite element simulation techniques to predict and resolve potential defects in production， thereby improving production efficiency， reducing costs， and ensuring product quality. This paper first employs Deform-3D finite element software to simulate the cold forging process of spherical washers. Through simulations， potential issues such as uneven metal flow， poor filling， and surface cracking are identified and addressed. To ensure product quality， a two-stage cold forging process consisting of pre-forging and final forging is designed. In the pre-forging stage， a cylindrical structure is formed to provide metal accumulation for the complex internal spline areas， ensuring smooth subsequent forming. The final forging stage uses precise die design to control metal flow， ensuring accurate formation of the end surfaces and splines of the forged part. Simulation results show that the metal can uniformly fill the die cavity， effectively preventing excessive flash and mitigating defects such as insufficient filling and folding. This process design significantly improves the forming precision of spherical washers， reduces mold development and testing costs， and lowers R&D expenses， providing reliable data support for actual production. In the trial production， the process parameters consistent with the simulation were applied， and the produced spherical washer components were of good quality， with smooth surfaces， no cracks， and dimensional accuracy within tolerance， confirming the feasibility of the process design. This paper offers an effective cold forging process for high-quality production of spherical washers， while optimizing the forming process through finite element simulation， reducing production costs and R&D risks. The methodology provides important references for the manufacture of other complex structural parts.