目      錄
1.緒論…………………………………………………………………………………… 1
1.1  課題的研究目的和意義…………………………………………………………1
1.2  相關(guān)情況綜述……………………………………………………………………2
1.2.1 冷擠壓技術(shù)的發(fā)展概況…………………………………………………2
1.2.2 有限元數(shù)值模擬技術(shù)的發(fā)展和應(yīng)用……………………………………4
1.3  課題的主要工作…………………………………………………………………8
2.數(shù)值模擬模型的建立及相關(guān)問(wèn)題的處理………………………………………9 
2.1 幾何模型的建立…………………………………………………………………9
2.2 材料性能的施加…………………………………………………………………10
2.3 摩擦邊界條件的處理……………………………………………………………11
2.4 接觸分析…………………………………………………………………………13
2.5 網(wǎng)格自適應(yīng)與網(wǎng)格重劃分………………………………………………………14
2.6 后處理過(guò)程中的一些技術(shù)問(wèn)題的處理…………………………………………15
2.7 有限元模型中其它關(guān)鍵問(wèn)題的處理……………………………………………15
2.8 小結(jié)………………………………………………………………………………16
3.彈丸藥筒冷擠壓成形過(guò)程的數(shù)值模擬…………………………………………17
3.1 剛塑性有限元基本理論…………………………………………………………17
3.2 影響金屬塑性變形和流動(dòng)的因素………………………………………………19
3.3 擠壓過(guò)程數(shù)值模擬………………………………………………………………20
3.3.1 模型的簡(jiǎn)化………………………………………………………………20
3.3.2 工藝參數(shù)對(duì)擠壓過(guò)程的影響……………………………………………21
3.4 小結(jié)………………………………………………………………………………25
4.彈丸藥筒冷擠壓成形工藝研究 …………………………………………………27
4.1 引言………………………………………………………………………………27
4.2 工藝方案的制定…………………………………………………………………27
4.3 設(shè)備選用…………………………………………………………………………27
4.3.1 毛坯加熱設(shè)備及方法……………………………………………………27
4.3.2 擠壓設(shè)備的選用…………………………………………………………27
4.4 模具設(shè)計(jì)…………………………………………………………………………28
4.4.1 模具材料的選用…………………………………………………………28
4.4.2 模具結(jié)構(gòu)設(shè)計(jì)……………………………………………………………30
4.5 擠壓工藝實(shí)施……………………………………………………………………34
4.5.1 毛坯的制備………………………………………………………………34
4.5.2 毛坯表面處理與潤(rùn)滑……………………………………………………34
4.5.3 擠壓工藝參數(shù)的選擇……………………………………………………36
4.5.4 冷擠壓過(guò)程中的有效潤(rùn)滑………………………………………………37
4.5.5 實(shí)驗(yàn)結(jié)果…………………………………………………………………38
4.6 小結(jié)………………………………………………………………………………38
5.彈丸藥筒冷擠壓模具失效分析 …………………………………………………40
5.1 模具失效分析概述………………………………………………………………40
5.2 冷擠壓凸模損壞的基本形式……………………………………………………41
5.3 彈丸藥筒擠壓模具的失效形式…………………………………………………44
5.4 彈丸藥筒擠壓模具的有限元分析………………………………………………46
5.4.1 有限元模型的建立………………………………………………………46
5.4.2 模具溫度場(chǎng)分析…………………………………………………………46
5.4.3 模具應(yīng)力場(chǎng)分析…………………………………………………………48
5.5 模具失效解決方案………………………………………………………………49
5.6 小結(jié)………………………………………………………………………………54
結(jié)論 
參考文獻(xiàn)
致謝

摘要
本文以某彈丸藥筒擠壓成形為研究對(duì)象，對(duì)該零件的擠壓成形過(guò)程及其模具的工作狀況進(jìn)行了數(shù)值模擬，制定了該擠壓件的成形工藝，并對(duì)模具進(jìn)行了失效分析，這對(duì)于保證成形件的質(zhì)量及提高模具的使用壽命，均具有積極的意義。
根據(jù)模擬分析的需要，建立了模具的幾何模型以及模擬過(guò)程的剛塑性有限元模型，并對(duì)模擬中邊界情況的定義、材料性能的施加、設(shè)備速度的選取和網(wǎng)格的劃分等關(guān)鍵問(wèn)題進(jìn)行了分析，為模擬和仿真的順利進(jìn)行打下了基礎(chǔ)。
應(yīng)用有限元數(shù)值模擬方法，對(duì)彈丸藥筒擠壓過(guò)程進(jìn)行了二維數(shù)值模擬。討論了摩擦條件、變形速度對(duì)變形過(guò)程中等效應(yīng)變、等效應(yīng)力以及擠壓力的影響，確定了合理的變形工藝參數(shù)。模擬結(jié)果顯示：擠壓速度在10mm/s時(shí)，最適宜該零件的生產(chǎn)。
在數(shù)值模擬結(jié)果分析的基礎(chǔ)上，制定了該彈丸藥筒擠壓成形的工藝方案，并進(jìn)行了生產(chǎn)試制。試驗(yàn)結(jié)果表明，用該擠壓工藝生產(chǎn)該零件，零件符合要求。
經(jīng)過(guò)批量生產(chǎn)后，擠壓凸模過(guò)渡部位斷裂，導(dǎo)致模具失效。本文采用有限元數(shù)值模擬軟件對(duì)凸模擠壓過(guò)程中的溫度場(chǎng)、應(yīng)力場(chǎng)進(jìn)行了分析，找出其失效的主要原因，提出了改進(jìn)方案并進(jìn)行了試驗(yàn)，有效的提高了模具的壽命。

關(guān)鍵詞：彈丸藥筒，擠壓成形，數(shù)值模擬，模具失效分析

Analysis and Experimental Study on the cartridge Extrusion
Abstract

Take the extrusion of a cartridge as the research object, the numerical simulation of forming process and working condition of die are studied in this paper. The technology of the extruded part has been stipulated, and the failure analysis has been studied. Those are in favor of increasing the part and the service life of die.
Firstly, the geometric model of die and rigid-plastic finite element model of simulation are built according to the demand of simulation analysis. The definition of interface condition between die and workpiece, the adding of material parameters, forming velocity of machine and mesh, is also done. It is the base of the following computer simulation.
Through numerical simulation of finite element method (FEM), the course of extrusion of the cartridge is simulated. The forming of the deformation rate and friction are discussed which impact equivalent strain, equivalent stress and extrusion force. The analysis showed that it is beneficial to forming when the extrusion is 10mm/s.
Based on the result of the FEM simulation, the extruded forming technology of the cartridge has been stipulated, and the physical experiment is achieved. The result shows that it is feasible to produce cartridge with this extrusion technology.
Through quantity production, the transition location of extruded die of the cartridge fractured. It resulted in the ineffectiveness of die. The stress and temperature field of die in the extrusion processes is analyzed using simulation software of finite element method. The main reason of ineffectiveness of die is found, and the improving project is put forward, effectively improved the life of the mold.

Key words: the cartridge, extrusion forming, numerical simulation, invalidation analysis of die