基于数值模拟汽车发动机活塞销挤压成形过程研究

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中图分类号：U463.67 文献标识码：A 文章编号：1003-8639（2025）10-0145-03

【Abstract】Aiming at the problems such as high material consumption，high cost and low effciency existing inthe traditional machining processof automotive engine piston pins，this paper proposes tooptimize the manufacturing process bycombining extrusion forming technologywith numerical simulation methods.By establishingathree-dimensional finite elementmodelofthe piston pin （withadiameterof 16mmandalengthof 60mm），the extrusionforming processof42CrMo alloy steel was simulated using DEFORM-3D software，and the influences of key parameters such as damage factors， folding Angledefects，and the variation curveofload with timeontheformingqualitywere analyzed.Research shows that optimizing the extrusion speed can significantlyreduce therisk of cracking.The maximum damage factorin the simulation is 0.248，andno cracking occurs.Byoptimizing the moldstructure （adjusting theentryAngleandlubricationconditions）， themaximum folding Angle is 234∘ （lower than the safety threshold of 270∘ ），avoiding foldingdefects.The maximum extrusion force reaches 14，080kN （based on a 16OOt press）. The coordinated optimization of extrusion speed， temperature and die design can enhance the uniformity of material flow.

【Key words】piston pin;extrusion forming;numerical simulation;damage factor;folding corner defect; process optimization

0 引言

随着世界汽车制造业的高速发展，人们对汽车发动机各关键部位的要求逐渐向高端化发展，作为连接活塞和连杆的中间部件，活塞销的品质直接影响发动机的寿命和可靠性。（剩余3992字）