The Fomring Process Optimization And Die Analysis Of The Fluid Coupling Shaft

Cold extrusion technology is an advanced production technology with the characteristics of high precision, high efficiency, high quality and low consumption,which belongs to the near net shape, has been used in the small and medium-sized forging scale production widely. Cold extrusion parts has good mechanical properties and mechanical properties because they are under the three-dimensional pressure during the forming process.The fluid coupling shaft studied in this paper is a relatively new type of flexible vehicle connection means,requiring high mechanical properties, such as strength,toughness, fatigue resistance and surface hardness to transmit motion and torque.Fluid coupling shaft originally produced by warm extrusion technology, the parts appear insufficient strength and poor surface quality. Using the finite element simulation technology based on the DEFORM platform to analysis the warm extrusion process, the cold extrusion process was proposed combined with the actual situation.The cold extrusion process improve the mechanical properties of fluid coupling shaft, and guarantee the accurate parts size and optimum surface quality instead of warm extrusion. The new process shorten the production cycle,significantly reducing energy consumption and greatly improved labor productivity.The fluid coupling shaft is the shaft parts with variable cross-section and a large deformation which is difficult to be formed in one step. Establish the cold extrusion process as following:forward extrusion 1 — forward extrusion 2— upset extruding— heading flat— coining. Cold extrusion process includes more steps,the mold design cycle and mold debugging difficult would be greatly increased in actual production. Simulating various forming processes based on the DEFORM platform to validate the optimized process and accurately describe each step in the stress field,strain field, velocity field. Analysis the formability of the new technology and predict the defect may arise in the forming process to validate process,optimize the process parameters and eliminate molding defects. This paper also analysis different parts of the microstructure of the fluid coupling shaft in two processes, and ultimately determine the cold extrusion to be the more suitable process combined with the results of finite element simulation.The metal is under the three-dimensional pressure during the forming process with a high unit force,the combination concave die can reduce the the mold stress significantly. This paper design the combination concave die combined with the numerical simulation can improve the mold life effectively.