锻压技术

基于有限元的法兰传动轴锻造工艺仿真及模具结构改进

英文标题：Forging process simulation and die structure improvement on flange drive shaft based on finite element

作者：曾义聪徐海良

分类号：TG315.2

出版年,卷(期):页码：2022,47(11):187-195

摘要：

某法兰传动轴经镦粗、一次挤压、二次挤压、预锻、终锻等5道工序成形，经长期生产发现其中工序3的模具磨损失效快、换模频率高，严重影响了产品的生产效率。为解决该问题，尝试对工序3的模具结构进行改进，根据其结构特征设计了两种改进方案，并基于Deform-3D分别进行了建模与仿真。首先，对原工艺进行了数值分析，初步验证了Archard修正模型的可靠性；其次，对改进后方案中锻件成形的完整度以及金属流线变化进行了分析，判断锻件是否存在成形缺陷，并比较了改进前、后模具磨损的变化情况；最后，对模拟分析结果进行了试模验证。结果表明：试验结果与模拟结果一致性较好，建模分析准确，改进后方案能够实现锻件的成形，其中方案1的成形效果更好，在不影响工序4的模具寿命的前提下，工序3的模具平均寿命从3472件提高至6235件，很好地解决了企业的难题。

A flange drive shaft was formed by five processes, including upsetting, primary extrusion, secondary extrusion, pre-forging and final forging，and after long-term production, it was found that the mold wear and failure of process 3 was fast and the mold change frequency was high, which seriously affected the production efficiency of product. Then, in order to solve this problem, the mold structure of process 3 was improved. Furthermore, two improvement schemes were designed according to its structural characteristics, and the modeling and simulation were carried out respectively based on Deform-3D. Firstly, the original process was numerically analyzed to preliminarily verify the reliability of Archard modified model. Secondly, the forming integrity and the change of metal streamline for forgings in the improved scheme were analyzed to judge whether there were forming defects in forgings, and the change conditions of mold wear before and after improvement were compared. Finally, the simulation analysis results were verified by test. The results show that the test results are in good agreement with the simulation results, the modeling analysis is accurate, the improved scheme can realize the forming of forgings, and the forming effect of scheme 1 is better. Thus, in the premise of not affecting the mold life of process 4, the average mold life of process 3 is increased from 3472 pieces to 6235 pieces, which solves the problem of enterprise very well.

基金项目：

国家自然科学基金面上项目（51375499）

作者简介：曾义聪（1973-），男，硕士，副教授，E-mail：zycong0075@163.com；通信作者：徐海良（1965-），男，博士，教授，E-mail：csuxhliang@aliyun.com

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