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摘要：
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针对RV减速器输出盘锻件在首次试生产过程出现的模具无法闭合以及6个小凸台充填不足的缺陷，制定了镦粗-预锻-终锻的成形工艺。以锻件上6个小凸台充填完全为切入点进行了第1次预锻模膛设计，在试生产过程中虽然锻件基本充足，但是出现了折叠的缺陷。运用有限元模拟软件DEFORM-3D对试生产过程进行数值分析。结果表明，由于预锻件的设计不合理导致金属流动速度不均匀，多股材料相汇合，从而产生折叠的缺陷。因此，根据折叠产生的原因重新设计了预锻模膛，并进行了有限元模拟验证，结果显示金属流动合理，材料之间的流动汇合基本消失，最终得到了合格的锻件。
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For the problem of the die failed to close and six small bosses of incomplete filling during the first forging output flange of RV reducer, upsetting-pre forging-final forging process was formulated, and the first blocker was designed by the requirement of six small bosses to be filled on forging. However, in the process of trial production, although the forging was filled enough, the folding defects still appeared. Therefore, numerical analysis was conducted by software DEFORM-3D. The results show that the design of pre-forging is unreasonable resulting in uneven metal flow speed, and the confluence of multistrand material causes the folding defects. Thus, the blocker is redesigned considering the reason of folding appearance, and then a verification by finite element simulation is carried out. The result shows that the metal flow is reasonable, and there is almost no metal confluence. Finally, a qualified forging is obtained.
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基金项目：
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国家自然科学基金资助项目（51775249）
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作者简介：
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作者简介：胡晓峰（1992-），男，硕士研究生
E-mail：hxfkxx0912@163.com
通讯作者：王雷刚（1963-），男，博士，教授，博士生导师
E-mail：lgwang@mail.ujs.edu.cn
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