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研究了锌质粘贴式平衡块冷镦挤成形的可行性,根据零件要求设计了镦挤模具。通过Deform-3D有限元模拟其塑性成形过程,发现在飞边区域损伤因子和表面延伸率较大,零件主体部分成形质量良好;成形载荷峰值低于理论计算值10%左右。按拟定工艺路线生产的零件重量误差在±0.5 g以内;相较于压铸件,零件内部组织更致密、硬度提高了1倍、冲击韧性提高了2倍以上,模具寿命超过15万件,相当于压铸模具寿命的5倍;材料利用率提高了20%左右,避免了压铸过程熔融锌锭工序,显著降低了产品能耗。
The feasibility of cold heading extrusion of zinc paste type balance block was studied, and the upsetting extrusion die was designed according to the requirements of the part. Deform-3D finite element simulation of its plastic forming process showed that the damage factor and surface elongation in the flash area were large, and the forming quality of the main part of the part was good. The peak value of forming load was less than 10% of the theoretical value. The weight error of the parts produced according to the proposed process is within ± 0.5 g. Compared with the die-casting parts, the internal parts of the parts are denser, the hardness is increased by 1 time, the impact toughness is increased by 2 times and the mold life is more than 150,000 pieces, Die-casting mold life of 5 times; material utilization increased by about 20%, to avoid the melting process of zinc ingot casting process, significantly reducing energy consumption.