摘 要:实际镦粗应用中，经常会遇到高径比超出正常范围的近等截面长轴件的镦粗实例，要合理地处理这类的问题，则需要提出合理的方案出来，使工件在镦粗过程中能够在不失稳的情况下，成功得到所需形状的工件。通过模具结构的改进及合理的设计，可以快速方便的设计出所需的整套模具并对其进行进一步的完善，这就大大提高了工作效率，同时也大大地节约了资源。

   锻造在实际的生活中有着广泛地应用，镦粗正属于锻造中冷锻的一种，本文主要介绍和近等截面大高径比防失稳镦粗模具设计相关的方案的设计过程，主要包括设计方案的的提出，再到各个零件的结构设计及整套模具的成形，最后对其镦粗过程进行模拟，再通过验证进行不断地完善修改，以得到能够解决此问题的一套方案；此外，在设计的过程中，还涉及到了对压力机及各个模具材料的选取以及选取原则，需要根据坯料的选取以及各个零件的工作环境及受力情况进行合适的选取。对于高径比大于3的试样在镦粗过程中失稳现象时有发生，所以提出可靠实用的方案对于生产来说及其重要，并且还需要对所设计的模具通过DEFORM-3D来进行模拟，来检测所设计的模具的可靠性以及所得到的零件是否符合要求。通过使用Pro/E与DEFORM-3D来进行镦粗模具辅助设计以及模拟分析可以不仅大大降低生产成本，而且还将设计的精确度大大地提高了、同时也尽可能地缩短了工作时长，因此可以大大提高生产效率。

关键词：大高径比试样；镦粗；防失稳；模具设计；成形模拟

Abstract:In the actual application of the upsetting, often encounter the ratio of height to diameter beyond the normal range of nearly uniform long axis parts upsetting example, to reasonably deal with this kind of problem, you need to put out a reasonable scheme, so that the workpiece can not be in the unstable situation in the upsetting process, successfully to workpiece the required shape. With the continuous development of science and technology, and through the application of computer simulation software, you can quickly and easily design the whole mold required and its further improvement, which greatly improves the work efficiency, but also saves resources greatly.

Forging have been widely used in real life, a kind of upsetting is forging cold forging, this paper mainly introduces and nearly uniform with large ratio of height to diameter design process related to the design scheme of lost stability upsetting die, mainly including the design scheme is put forward, forming and structure design and mold set the various parts, finally the upsetting process is simulated, and then through the analysis of the results of wrong constantly modify, in order to get a set of solutions to solve this problem; in addition, in the design process, but also involves the selection of mould materials and various press and the selection principle, according to the need of blank selection and various parts of the work environment and stress condition were selected appropriately. For the large ratio of height to diameter specimen during upsetting instability phenomena have occurred, so it is a reliable and practical scheme for production is very important, and also need to moulds designed by DEFORM-3D to simulate the mold to detect whether the reliability design of the parts meet the requirements. For the upsetting die aided design and simulation analysis by using Pro/E and DEFORM-3D can not only greatly reduce the production cost, but also greatly improves the accuracy of design, but also as far as possible to shorten the work time, so it can greatly improve the production efficiency.

Key words: large and high aspect ratio test specimens; upsetting; stability prevention; die design; forming simulation

目  录

第一章  绪论 1