Fem Simulation Analysis And Parameter Optimization Of The Cold-drawing Drive Shaft Process With Ultrasonic Vibration

The cold-drawing drive shaft with ultrasonic vibration is a process of cold-drawing drive shaft by exerting ultrasonic vibration during the cold-drawing. The project is aimed at solving some problems in conventional cold-drawing: low dimensional accuracy(below IT8), easily to be outworn for dies, poor surface quality, and so on. Reducing the friction and the cold-drawing force by exerting ultrasonic vibration could realize the precisely cold-drawing so that products could be directly assembled with bearings. Under conditions of pretreatment processes(pickling, phosphating, neutralization, saponification etc.) and optimized parameters of the die structure, the paper completes following researches about the cold-drawing drive shaft with ultrasonic vibration: the FEM simulation analysis, the optimization of processing parameters, primarily designing the experimental device.Firstly, taking drawing Φ50mm drive shaft of 45 steel as the research object and exerting axial loads by using the method of ‘Synchronous loading, Multi-step solution’, this paper completes the FEM simulation analysis for conventional cold-drawing and cold-drawing drive shaft with ultrasonic vibration by using ANSYS Workbench and Pro/E software. The results show: the ultrasonic vibration could effectively reduce the drawing force and friction, but the friction decreases less than the drawing force. That is mainly due to the effect of reducing friction and load that is caused by intermittent contacts and high-velocity impacts between dies and workpieces. In addition, the friction of the cold-drawing drive shaft with ultrasonic vibration is smaller than conventional drawing, and the friction in the sizing zone is larger than in the reducing zone. Moreover, the effect of ultrasonic vibration in the reducing zone is more obvious than in the sizing zone.Secondly, by using the orthogonal experimental method, this paper conducts the simulation optimization design on three main processing parameters(amplitude, cold-drawing velocity, frequency) of the cold-drawing drive shaft with ultrasonic vibration. The results show that the effect order of three main parameters on the cold-drawing drive shaft with ultrasonic vibration: Amplitude is the biggest; Frequency is better; Cold-drawing velocity is relatively smaller. The best processing parameters are listed as follows after optimization: V=9m/min; f=40k Hz; A=0.06 mm. The results of simulation between cold-drawing under the condition of optimized parameters and conventional cold-drawing are comparatively analyzed. That results show: Compared with conventional cold-drawing, the average value of cold-drawing force under the condition of optimized parameters reduces 43.39%; The contact compressive stress in the reducing zone reduces 15.30%; The contact compressive stress in the sizing zone reduces 11.87%.Lastly, taking the LW30 drawing machine as the experimental platform and taking drawing Φ9.6mm bar as the research object according to the national standard of dies, the cold-drawing device with ultrasonic vibration is designed by using Pro/E software. There are the ‘hollow’ transducer, the ‘hollow’ horn and the ‘embedded’ fixed way of the die in the design. It is better for the installation-adjustment and simplifying the ultrasonic vibration device.