滚动直线导轨滑块拉拔成形工艺优化及有限元分析
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河北省重点研发计划项目(23311004D);中央引导地方科技发展资金项目(246Z1020G)


Optimization and finite element analysis of the drawing process for rolling linear guide slider
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    摘要:

    针对河北某企业滚动直线导轨副中滑块5道次冷拉拔成形,拉拔道次过多导致生产成本增加的问题,研究入模锥角、定径带长度等对坯料变形的影响,确定最优参数组合以减少拉拔道次,以降低生产成本。建立滑块拉拔成形有限元模型,以拉拔过程中坯料最小截面应力是否超过材料抗拉强度作为正交试验的失效判据,以入模锥角、定径带长度、摩擦因数、拉拔速度4个工艺参数为影响因素进行正交试验分析,研究工艺参数对成形过程中坯料最小截面处应力的影响,以及相互作用的主次关系;结合极差分析法(R值法)得到最优参数组合,通过理论计算优化拉拔道次,并重新设计模具定径带尺寸结构。结果表明:优化后的拉拔道次从5道次减少为3道次,各工艺参数对坯料最小截面所受应力的影响程度大小依次为入模锥角、定径带长度、摩擦因数、拉拔速度;最优工艺参数为入模锥角为5.0°,定径带长度为10 mm,摩擦因数为0.06,拉拔速度为83 mm/s;数值模拟优化后3个道次拉拔时,坯料最小截面所受应力大小均低于材料抗拉强度(885 MPa),且安全系数大于1.25;理论上,3道次拉拔的安全系数均满足要求,验证了优化方案的可行性。研究揭示了工艺及模具关键参数影响拉拔应力的主次关系,为滚动直线导轨滑块多道次拉拔成形工艺优化提供了一定理论参考。

    Abstract:

    Aiming to address the issue of increased production costs caused by the five-pass cold drawing forming for the sliding block in the rolling linear guide pair in a factory in Hebei Province, this study investigated the influence of parameters such as die cone angle and sizing belt length on billet deformation. The objective was to determine the optimal parameter combination to reduce the number of drawing passes and lower production costs. A finite element model for slider drawing and forming was established, and whether the stress at the minimum cross-section of the blank exceeded the tensile strength of the material during the drawing process was taken as the failure criterion for the orthogonal experiment. An orthogonal test analysis was conducted with four process parameters including die cone angle, sizing belt length, friction coefficient, and drawing speed, as influencing factors, to study the influence of process parameters on the stress at the minimum cross-sectional area of the billet during the forming process, as well as the primary and secondary relationships of interactions. The optimal parameter combination was obtained by combining range analysis (R-value method). Finally, the number of drawing passes was optimized through theoretical calculation, and the size structure of the die sizing belt was redesigned. The results indicate that the optimized drawing passes are reduced from five to three, and the influence degrees of various process parameters on the stress acting on the minimum cross-section of the billet are in the following order: die cone angle, sizing belt length, friction coefficient, and drawing speed. The optimal process parameters are as follows: the cone angle of the mold is 5 °, the sizing belt length is 10 mm, the friction coefficient is 0.06, and the drawing speed is 83 mm/s. The simulation results indicate that after optimization, the stress on the billet’s minimum cross-section remains below the tensile strength of the material (885 MPa) during all three-pass drawing passes, and the safety factor exceeds 1.25. Theoretical calculations show that the safety factors of the three-pass drawing all meet the requirements, which verifies the feasibility of the optimization scheme. The study reveals the primary and secondary relationships between key parameters of process and mold affecting drawing stress, providing theoretical reference for optimizing the multi-pass drawing process of rolling linear guide sliders.

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高 岩,王润铮,黎 旺,马海坤,莫宏岗,韩鹏彪.滚动直线导轨滑块拉拔成形工艺优化及有限元分析[J].河北科技大学学报,2026,47(1):73-85

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  • 收稿日期:2025-07-29
  • 最后修改日期:2025-11-03
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  • 在线发布日期: 2026-02-09
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