目      錄
1.緒論…………………………………………………………………………………… 1
1.1  課題的研究目的和意義…………………………………………………………1
1.2  相關情況綜述……………………………………………………………………2
1.2.1 冷擠壓技術的發(fā)展概況…………………………………………………2
1.2.2 有限元數(shù)值模擬技術的發(fā)展和應用……………………………………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問題的處理………………………………………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)格自適應與網(wǎng)格重劃分………………………………………………………14
2.6 后處理過程中的一些技術問題的處理…………………………………………15
2.7 有限元模型中其它關鍵問題的處理……………………………………………15
2.8 小結………………………………………………………………………………16
3.彈丸藥筒冷擠壓成形過程的數(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的因素………………………………………………19
3.3 擠壓過程數(shù)值模擬………………………………………………………………20
3.3.1 模型的簡化………………………………………………………………20
3.3.2 工藝參數(shù)對擠壓過程的影響……………………………………………21
3.4 小結………………………………………………………………………………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 設備選用…………………………………………………………………………27
4.3.1 毛坯加熱設備及方法……………………………………………………27
4.3.2 擠壓設備的選用…………………………………………………………27
4.4 模具設計…………………………………………………………………………28
4.4.1 模具材料的選用…………………………………………………………28
4.4.2 模具結構設計……………………………………………………………30
4.5 擠壓工藝實施……………………………………………………………………34
4.5.1 毛坯的制備………………………………………………………………34
4.5.2 毛坯表面處理與潤滑……………………………………………………34
4.5.3 擠壓工藝參數(shù)的選擇……………………………………………………36
4.5.4 冷擠壓過程中的有效潤滑………………………………………………37
4.5.5 實驗結果…………………………………………………………………38
4.6 小結………………………………………………………………………………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 模具溫度場分析…………………………………………………………46
5.4.3 模具應力場分析…………………………………………………………48
5.5 模具失效解決方案………………………………………………………………49
5.6 小結………………………………………………………………………………54
結論 
參考文獻
致謝

摘要
本文以某彈丸藥筒擠壓成形為研究對象，對該零件的擠壓成形過程及其模具的工作狀況進行了數(shù)值模擬，制定了該擠壓件的成形工藝，并對模具進行了失效分析，這對于保證成形件的質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程的剛塑性有限元模型，并對模擬中邊界情況的定義、材料性能的施加、設備速度的選取和網(wǎng)格的劃分等關鍵問題進行了分析，為模擬和仿真的順利進行打下了基礎。
應用有限元數(shù)值模擬方法，對彈丸藥筒擠壓過程進行了二維數(shù)值模擬。討論了摩擦條件、變形速度對變形過程中等效應變、等效應力以及擠壓力的影響，確定了合理的變形工藝參數(shù)。模擬結果顯示：擠壓速度在10mm/s時，最適宜該零件的生產(chǎn)。
在數(shù)值模擬結果分析的基礎上，制定了該彈丸藥筒擠壓成形的工藝方案，并進行了生產(chǎn)試制。試驗結果表明，用該擠壓工藝生產(chǎn)該零件，零件符合要求。
經(jīng)過批量生產(chǎn)后，擠壓凸模過渡部位斷裂，導致模具失效。本文采用有限元數(shù)值模擬軟件對凸模擠壓過程中的溫度場、應力場進行了分析，找出其失效的主要原因，提出了改進方案并進行了試驗，有效的提高了模具的壽命。

關鍵詞：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