Finite Element Analysis Of Cold Forging In Pole Piece Of Electrical Motor

Pole pieces, key parts on electrical motor, reduce the reluctance of the air-gap; improve the static magnetic field distributions and fix the excitation windings. Therefore, high material quality, dimension precision and surface quality should be attended. In this paper, taken the pole piece cold forging as the research subject, the forming technology and the numerical simulation of the forming process are studied, which is important to enrich and develop the theory and technique of the cold forging and improve the forming design level of pole piece parts' cold-and-precise forging.During recent years, with the rapid development of computer technology, the technology of FEM simulation has achieved great progresses. In this research a kind of electrical motor pole piece was introduced, whose model was made by the CAD technology. The forming process of electrical motor pole piece was simulated by FEM software. The transformations of the fields during the process of metal forming were investigated, the tendency of metallic flow was forecasted and the rules how various items affect the forming load, metallic flow, the life of dies were discovered. The factors include the different rough thickness, the frictional condition, etc. And the most suitable rough thickness and frictional condition were made certain. Finally some experiments were made. Contrasting the simulation result with the experiment result.During the research of cold forging forming process of electrical motor pole piece, we have used the most popular software DEF0RM-3D which used for volume shaping. Through the simulation of the process, we find there are some defect in condition of filling after finish forging and be similar to the fact of production. Analyzed that by means of the theory of diffluent surface, found the cause of filling defects and proposed solutions. On this basis, we improve the process; optimize the rough size and the frictional condition to achieve the production need.The theory of cold forging, technology of FEM simulation and mould CAD/CAM are integrated through this research, which helps to shorten developing period, prolong life-span of die, and cut down the cost, etc. The progeny of the research can provide accordance for other pole piece production and mould design and it also can be used for the leading production directly.