锻压技术

汽车前轴第1道次辊锻成形工艺有限元模拟与实验

英文标题：Finite element simulation and experimental research on the automobile front axle beam in the preliminary roll forging process

作者：吕霄刘艳雄王孝文

单位：武汉理工大学

关键词：汽车前轴辊锻成形 Deform-3D 辊锻角速度前轴锻件

分类号：TG316

出版年,卷(期):页码：2017,42(2):5-11

摘要：

建立了前轴辊锻第1道次模型，并利用Deform-3D软件进行模拟仿真，通过与实际辊锻成形前轴进行对比，确定了合理的边界条件，并对其准确性进行了验证。由分析可知，摩擦因子为0.6、传热系数为11时，模拟结果与实验结果对比误差最小。研究了传热系数、摩擦因子、初始温度、辊锻角速度、模具板簧处圆角等工艺参数对辊锻第1道次成形的影响规律。结果表明，摩擦因子增大和初始温度升高，锻件弹簧板中心距和最大展宽均随之增大。转动角速度增大，弹簧板中心距、最大展宽逐渐减小。锻件总长和最大展宽随着模具板簧处圆角增大而减小。通过第1道次辊锻制坯工艺优化，降低了终锻成形载荷，提高了终锻模具型腔填充程度与材料利用率。

A 3D finite element (FE) model of the preliminary roll forging process for the automobile front axle was established, and the numerical simulation was conducted by the Deform-3D platform. Then, a reasonable boundary condition was confirmed by comparing the simulation result with actual roll forging of front axle, and its accuracy was verified. The analysis shows that the error between the simulation and experimental results is the smallest with friction factor of 0.6 and heat transfer coefficient of 11. It was analyzed the influences of the heat transfer coefficient, friction factor, initial temperature of billet, rotational speed of roll forging, die fillet of spring on the preliminary roll forging process of automobile front axle beam. The results show that when the friction factor and the initial temperature increase, the center distance of spring and the maximum width increase. As the rotational speed increases, the center distance of spring and the maximum width gradually decrease. The general forging length and the maximum width decrease with the increase of die fillet. Thus, through the optimization of the preliminary roll forging process, the final forging load is reduced, and the utilization ratio of material is improved.

基金项目：

基金项目:教育部创新团队发展计划项目（IRT13087）

吕霄（1992-），男，硕士研究生刘艳雄（1985-），男，博士，副教授

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