锻压技术

基于有限元铝合金复杂精密锻造模具失效分析及优化

英文标题：Failure analysis and optimization on aluminum alloy complex precision forging mold based on finite element

作者：金飞翔1 2 董奇1 2 徐梦洁1 黎诚3 秦强1 殷剑3 4 张春鹏1 2

单位：1.合肥学院先进制造工程学院 2.合肥学院智能制造技术与应用协同创新中心 3.中机精密成形产业技术研究院(安徽)股份有限公司 4.中国机械总院集团北京机电研究所有限公司

分类号：TG319

出版年,卷(期):页码：2023,48(2):180-184

摘要：

针对6082铝合金内扣式消防接口成形过程中精锻模具失效的问题，考虑模具材料和热处理影响，采用试验法对比分析了模具材料和显微结构，并提出了模具结构和模具应力是导致模具失效开裂的主要原因。利用有限元分析法，建立了坯料和模具之间的本构关系，模拟了实际产品成形过程，对产品精锻模具进行了失效分析。通过对模具失效位置的应力进行分析，提出了模具结构的优化方案。试验结果表明，优化后模具失效开裂部位应力集中的现象得到了改善，模具最大应力值由1020 MPa 降至800 MPa。采用优化后的模具进行实际生产，模具使用寿命由500件提升至3000余件，并且模具表面磨损较轻，磨损处简单修复后可继续使用，有效地降低了模具成本,为铝合金精密成形的开发和模具寿命的提高提供了理论基础。

In view of the problem of precision forging mold failure in the forming process of 6082 aluminum alloy inner buckle fire protection interface, considering the influence of mold material and heat treatment, the material and microstructure of mold were compared and analyzed by experimental method, and it was found that the mold structure and mold stress were the main causes of mold failure and cracking. Then, the constitutive relationship between billet and mold was established by finite element analysis method, the forming process of the actual product was simulated, and the failure of the precision forging mold for product was analyzed. Furthermore, by analyzing the stress of the failure position for mold, the optimization scheme of the mold structure was proposed. The experiment results show that the phenomenon of stress concentration in the failure cracking positions of the mold is improved after optimization, and the maximum stress of the mold is reduced from 1020 MPa to 800 MPa. The optimized mold is carried out for the actual production, the service life of the mold is increased from 500 pieces to more than 3000 pieces, the surface wear of the mold is light, and the worn part can be used after simple repair, which effectively reduces the cost of the mold. Thus, the research provides a theoretical basis for the development of aluminum alloy precision forming and the improvement of mold service life.

基金项目：

国家科技重大专项项目（2018ZX04020-004）；安徽省高等学校自然科学研究项目（KJ2018A0553）；合肥学院人才科研基金（18-19RC51，18-19RC52)；21年合肥学院研究生创新创业项目(21YCXL09)；安徽省新能源汽车暨智能网联汽车产业技术创新工程（wfgcyh2020477,wfgcyh2021439）

作者简介：金飞翔（1988-），男，博士，副教授，E-mail：brimetamtejfx@163.com

参考文献：

[1]徐华，胡双锋，付秀娟，等. 基于Deform的三缸曲轴锻模设计[J]. 锻压技术，2022，47(1)：161-167.

Xu H, Hu S F, Fu X J, et al. Design on forging die for three-cylinder crankshaft based on Deform [J]. Forging & Stamping Technology, 2022, 47(1): 161-167.

[2]张松泓，徐颖若. 基于响应面法发动机连杆热锻模具磨损失效分析[J]. 锻压技术，2021，46(7)：178-184.

Zhang S H, Xu Y R. Analysis on wear failure of hot forging die for engine connecting rod based on response surface method [J]. Forging & Stamping Technology, 2021, 46(7): 178-184.

[3]莫才颂，马李. 连杆锻造模具应力模拟及失效分析[J]. 工具技术，2020，54(8)：69-72.

Mo C S, Ma L. Stress simulation and failure analysis of connecting rod forging die [J]. Tool Engineering, 2020, 54 (8): 69-72.

[4]吴丹萍，叶能永，王蕾，等. 槽式爪极锥形孔成形中的模具失效分析及工艺优化[J]. 塑性工程学报，2020，27(9)：35-39.

Wu D P, Ye N Y, Wang L, et al. Failure analysis of dies and process optimization in conical hole of slotted claw pole forming [J]. Journal of Plasticity Engineering, 2020,27 (9): 35-39.

[5]李尧. 金属塑性成形原理[M]. 2版. 北京：机械工业出版社，2013.

Li Y. Principle of Metal Plastic Forming [M]. 2nd Edition. Beijing: China Machine Press, 2013.

[6]洪慎章. 实用热锻模设计与制造[M]. 2版. 北京：机械工业出版社，2016.

Hong S Z. Design and Manufacture of Practical Hot Forging Die [M]. 2nd Edition. Beijing: China Machine Press, 2016.

[7]范晓明，王旭坤，熊映，等. 热处理工艺对6082铝合金组织和性能的影响[J]. 特种铸造及有色合金，2018，38(5)：475-478.

Fan X M, Wang X K, Xiong Y, et al. Effects of heat treatment on microstructure and properties of 6082 aluminum alloy [J]. Special Casting & Nonferrous Alloys, 2018,38 (5): 475-478.

[8]董奇，金飞翔，秦强，等. 基于正交试验齿圈座热锻成形工艺优化[J]. 塑性工程学报，2021，28(8)：18-22.

Dong Q, Jin F X, Qin Q, et al. Optimization of hot forging process based on orthogonal test for gear ring seat [J]. Journal of Plasticity Engineering, 2021, 28(8): 18-22.

[9]金飞翔，谷曼，周林. 复杂异形件热弯曲成形关键工艺参数影响及优化[J]. 塑性工程学报，2020，27(9)：82-86.

Jin F X, Gu M, Zhou L. Influence and optimization of key process parameters of complex special-shaped parts in hot bending forming [J]. Journal of Plasticity Pngineering, 2020, 27 (9): 82-86.

[10]殷剑，黎诚，金康，等. 铝合金汽车前下摆臂成形工艺的有限元模拟与优化[J]. 锻压技术，2021，46(11)：74-82.

Yin J, Li C, Jin K, et al. Finite element simulation and optimization on forming process of automobile front lower sway arm for aluminum alloy [J]. Forging & Stamping Technology, 2021, 46(11): 74-82.

[11]GB/T 1299—2014, 工模具钢 [S].

GB/T 1299—2014, Tool and mould steels [S].

[12]王星，陈文琳. 链轨节锻造模具断裂分析及改进[A]. 2019年第九届全国地方机械工程学会学术年会论文集[C].郑州,2019.

Wang X, Chen W L. Fracture analysis and improvement of forging die for chain rail [A]. Proceedings of the 9th Annual Conference of China Local Mechanical Engineering Society[C].Zhengzhou,2019.

[13]李庆生, 李志,贺小华.锆-钛复合板焊接接头局部力学性能研究[J].稀有金属,2020,44(12):1240-1248.

Li Q S, Li Z, He X H. Local mechanical properties of welded joint of Zr/Ti cladding plate [J]. Chinese Journal of Rare Metals, 2020,44(12):1240-1248.

服务与反馈：

【本网站尚未开通全文下载服务】【加入收藏】