锻压技术

高压共轨锻件预制坯的形状优化设计

英文标题：Optimization design on shape of preform for high pressure common rail forgings

单位：1.山东大学材料液固结构演变与加工教育部重点实验室 2.金马工业集团股份有限公司

分类号：TG316

出版年,卷(期):页码：2021,46(12):1-5

摘要：

为了提高材料的利用率，对Q4041高压共轨锻件预制坯的形状进行了优化设计。根据实际生产中终锻件中间部位飞边量较大的情况，设计了哑铃型预制坯形状，提出了采用辊锻制坯代替现有制坯的工艺方法。设计了4种不同形状的预制坯形状，采用有限元软件对设计的预制坯进行了锻造过程模拟。采用机加工方式制备了预制坯，进行了实际的锻造实验，并与模拟结果进行对比，确定了4种辊锻预制坯方案中能够完全充满型腔且飞边量最小的预制坯形状。实验结果表明，有限元模拟结果与实际的锻造过程相一致，采用优化的预制坯进行锻造生产可以减少35%的飞边，因此，采用辊锻制坯工艺是可行的。

In order to improve the utilization rate of materials, the shape of preform for Q4041 high pressure common rail forgings was optimized and designed. Then, according to the large amount of flash in the middle part of final forgings in actual production, the shape of dumbbell preforms was designed, and the process method of using roll forging preform to replace the existing preform was proposed. Furthermore, four different shapes of preform were designed, and the forging process of preforms was simulated by finite element software. Finally, the preform was fabricated by machining, and the actual forging experiment was carried out. Compared with the simulation results, the preform shape which completely filled the cavity and had the least flash in the four roll forging preform schemes was determined. The experimental results show that the results of finite element simulation are consistent with those of the actual forging process, and the flash is reduced with 35% with the optimized preform in the forging production. Thus, the preform process by the roll forging is feasible.

基金项目：

山东省重大科技创新工程项目（2019JZZY010431）；日照市重大科技专项计划（2020CXZX1207）

马新武(1975-)，男，博士，教授 E-mail：maxinwu@sdu.edu.cn 通信作者：赵国群(1962-)，男，博士，教授

参考文献：

[1]王称心, 武美萍,何雪明,等. 共轨管材料属性对共轨压力的影响分析[J]. 机床与液压, 2015,43(13):52-54.

Wang C X, Wu M P, He X M, et al. Analysis on effect of common rail pipe maerial properties to common rail pressure[J]. Machine Tool & Hydraulics, 2015,43(13):52-54.

[2]李文平, 吴欲龙,苏晓东. 共轨管内增压工艺及其对疲劳性能影响的研究[J]. 汽车工艺与材料, 2020, (2):53-55.

Li W P, Wu Y L, Su X D. Common rail pipe boosting technology and its influence on fatigue performance[J]. Automobile Technology & Material, 2020, (2):53-55.

[3]李安康, 夏平,李向阳,等. 基于Workbench有限元分析的高压共轨管结构优化[J]. 机电设备, 2020,37(6):10-15.

Li A K, Xia P, Li X Y, et al. Structural optimization of high pressure common rail based on workbench finite element analysis[J]. Mechanical and Electrical Equipment, 2020,37(6):10-15.

[4]杨行. 基于双向渐进结构优化法的预成形优化设计研究[D]. 济南：山东大学,2019.

Yang H. Research on Preform Optimal Design Based on Bidirectional Evolutionary Structural Optimization [D]. Jinan:Shandong University, 2019.

[5]邵勇. 复杂形状叶片精密成形的预锻形状拓扑优化算法研究[D]. 上海: 上海交通大学,2014.

Shao Y. Reseach on Topological Algorithm for Preform Optimization of Complex Structural Blade in Precision Forging Process [D]. Shanghai: Shanghai Jiaotong University, 2014.

[6]赵新海, 赵国群,王广春. 金属体积成形预成形设计的现状及发展[J]. 塑性工程学报, 2000, 7(3):1-6.

Zhao X H, Zhao G Q, Wang G C. The current situation and development of preform design in bulk metal forming[J]. Journal of Plasticity Engineering, 2000, 7(3):1-6.

[7]白雪. 基于类等势场法的锻造预成形优化设计研究[D]. 济南：山东大学,2013.

Bai X. Study on Preform Shape Optimization in Forging Process Based on Quasiequipotential Field Method[D]. Jinan: Shandong University, 2013.

[8]李向阳，徐长达，周佑才，等. 基于响应面法的游艇转向臂锻造工艺优化 [J]. 锻压技术，2020,45(2):1-6.

Li X Y，Xu C D,Zhou Y C，et al. Optimization on forging process for yacht steering arm based on response surface method [J]. Forging & Stamping Technology，2020,45(2):1-6.

[9]李旭斌，吴昂，张治民，等. 高强铝合金异形复杂构件预成形优化设计 [J].锻压技术，2019,44(9):56-62.

Li X B，Wu A，Zhang Z M，et al. Preforming optimization design on highstrength aluminum alloy specialshaped complex components [J]. Forging & Stamping Technology，2019,44(9):56-62.

[10]李改丽. 粉末锻造连杆的数值模拟及其预制坯优化设计研究[D]. 济南：山东大学, 2017.

Li G L. Research on Numerical Simulation and the Preform Optimization of Connectiong Rod Powder Forging[D]. Jinan: Shandong University, 2017.

[11]刘玉赫. 大型刮板辊锻制坯模锻成形工艺研究[D]. 合肥:合肥工业大学, 2013.

Liu Y H. The Techics Research of Roll Forging Billet and Molding in Mining Scaper[D]. Hefei: Hefei University of Technology, 2013.

[12]李如雄, 王金铝. 汽车前轴制坯辊锻工艺分析与模具设计[J]. 机械设计与制造, 2010, (10):243-245.

Li R X, Wang J L. Blankmaking rollforging process and die design for automotive front axle[J]. Machinery Design & Manufacture, 2010,(10):243-245.

服务与反馈：

【本网站尚未开通全文下载服务】【加入收藏】