Shaped guide cylinder shaped cavity forming process based on numerical simulation

The car starting guide cylinder is a key component in the car starting system, as shown in Figure 1. The upper part is a special-shaped cavity, and the lower part is a spiral involute internal spline. The cutting process is used, the efficiency is low, the cost is high, and the internal quality is poor, which is far from meeting the performance requirements of the automobile manufacturer.

In this paper, a one-time back-extrusion forming method is proposed for the structural characteristics of the upper shaped cavity of the starting guide cylinder. The numerical simulation of the forming process is carried out based on DEFORM-3D software. The material flow, velocity field, stress and strain field are obtained through simulation. Distribution law and load-stroke curve. The visual analysis can better predict the defects that may occur in the forming process (such as corner filling, folding, reflow and fracture), and improve the forming process on this basis.

Forming process description

The accuracy of the upper shaped cavity of the starting guide cylinder is IT7~IT8. According to the structural characteristics of the guiding cylinder, through research and analysis, we determine that the guiding cylinder process is:

Cutting → peeling → spheroidizing annealing → shot blasting → pretreatment → positive extrusion → pier rough → drilling → spheroidizing annealing → shot blasting → pretreatment → back extrusion cavity (see Figure 2).

2. Finite element analysis

(1) Establishment of geometric model Since DEFORM-3D does not have geometric modeling function, the three-dimensional geometric model should be established in other three-dimensional software. This article uses UGNX software for geometric modeling and stores it as . STL format. Fig. 3a is a rough view before extrusion, and Fig. 3b and Fig. 3c are three-dimensional geometric models of a punch and a die, respectively.

For more information, please download the attachment or view Metalworking (Cold Processing), Issue 19, 2013:

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