大规格复杂曲面叶片精密模锻成形工艺设计及优化
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摘要
以大规格复杂曲面叶片锻件为例,介绍了复杂曲面叶片锻造模具的设计关键点——叶片旋转定位和投影面中心重合。预锻坯料采取变直径物料分配设计和定位设计,基于Deform-3D有限元模拟软件进行了精密模锻成形工艺优化,并在100 MN液压机上验证了工艺的可行性。结果表明:叶片旋转定位和投影面中心重合设计,减少了预锻坯料的偏移和滑动。预锻坯料总长度是重要尺寸,在终锻成形过程中,长度方向单边展宽不小于60 mm。预锻坯料进行了拍扁定位设计,解决了预锻坯料偏移和滑动问题。预锻坯料采取变直径物料分配并进行了尺寸优化,锻件充填完整,锻件飞边宽度均匀性标准差SD值达到最小。
For the complex curved blade forging with large specifications,the key points of design for complex curved blade forging mold were introduced,namely,the blade rotation positioning and the projection surface center superposition,and the material distribution and positioning design of variable diameter for pre-forging billet were adopted. Then,the process optimization of precision die forging was conducted based on the finite element simulation software Deform-3 D,and the feasibility of the process was verified by 100 MN hydraulic press. The results show that the design of blade rotation positioning and the projection surface center superposition reduces the offset and sliding of pre-forging billet. However,the total length of pre-forging billet is an important dimension,and the unilateral extension in the length direction is not less than 60 mm in the process of final forging. Furthermore,the pre-forging billet is designed with flat positioning which solves the problem of offset and sliding. Finally,the pre-forging billet was distributed with variable diameter,and its size was optimized. The forging is completely filled,and the standard deviation SD value of flash width uniformity reaches the minimum.
For the complex curved blade forging with large specifications,the key points of design for complex curved blade forging mold were introduced,namely,the blade rotation positioning and the projection surface center superposition,and the material distribution and positioning design of variable diameter for pre-forging billet were adopted. Then,the process optimization of precision die forging was conducted based on the finite element simulation software Deform-3 D,and the feasibility of the process was verified by 100 MN hydraulic press. The results show that the design of blade rotation positioning and the projection surface center superposition reduces the offset and sliding of pre-forging billet. However,the total length of pre-forging billet is an important dimension,and the unilateral extension in the length direction is not less than 60 mm in the process of final forging. Furthermore,the pre-forging billet is designed with flat positioning which solves the problem of offset and sliding. Finally,the pre-forging billet was distributed with variable diameter,and its size was optimized. The forging is completely filled,and the standard deviation SD value of flash width uniformity reaches the minimum.
引文
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[3]陈微,官英平,王振华.高钛6061铝合金轮毂精锻成形的微观组织模拟[J].塑性工程学报,2017,24(1):1-8.Chen W,Guan Y P,Wang Z H. Numerical simulation of micro-structure evolution for precision forging of high titanium 6061 alu-minum alloy wheels[J]. Journal of Plasticity Engineering,2017,24(1):1-8.
[4]孙红镱,陈佳,李峰.航空铝合金构件预制坯工艺优化研究[J].热加工工艺,2013,42(7):86-88.Sun H Y,Chen J,Li F. Research on preform process of aviationaluminum alloy components[J]. Hot Working Technology,2013,42(7):86-88.
[5]雷金琴,徐磊,高永强,等.采用Deform-3D对5083铝合金车轮锻造过程的模拟研究[J].轻合金加工技术,2015,43(8):40-44.Lei J Q,Xu L,Gao Y Q,et al. Simulation of the forging processfor 5083 aluminum alloy wheels with Deform-3D[J]. Light AlloyFabrication Technology,2015,43(8):40-44.
[6]伍太宾,马斌,唐文平,等.预制坯形状尺寸和成形方法对铝合金连杆体闭塞锻造成形的影响[J].热加工工艺,2016,45(1):169-172.Wu T B,Ma B,Tang W P,et al. Effects of shape and size of pre-form and forming method on closed die forging process for alumi-num alloy connecting rod[J]. Hot Working Technology,2016,45(1):169-172.
[7]王松伟,张士宏,陈岩,等.某铝合金复杂锻件成形工艺设计及DEFORM-3D模拟优化[J].锻压技术,2018,43(5):154-161.Wang S W,Zhang S H,Chen Y,et al. Forming process designand DEFORM-3D simulation optimization for a complex aluminumalloy forging[J]. Forging&Stamping Technology,2018,43(5):154-161.
[8]石文超,薛克敏,李萍,等.摇臂等温精密成形工艺数值模拟及实验研究[J].塑性工程学报,2011,18(1):43-47.Shi W C,Xue K M,Li P,et al. Simulation and experimentalstudy on the isothermal forging of aluminium-alloy rocker arms[J]. Journal of Plasticity Engineering,2011,18(1):43-47.
[9]程俊伟,夏巨谌,戴护民,等.活塞尾锻造工艺分析及数值模拟[J].锻压技术,2006,31(4):1-4.Cheng J W,Xia J C,Dai H M,et al. Analysis of die forgingprocess for the piston tail part and numerical value simulation[J]. Forging&Stamping Technology,2006,31(4):1-4.
[10] Fang G,Lei L P,Zeng P. Three-dimensional rigid-plastic finiteelement simulation for the two-roll cross-wedge rolling process[J]. Journal of Materials Processing Technology,2002,129:245-249.
[11] Zhou J,Xiao C,Yu Y Y,et al. Influence of tool parameters ontool wear in two-rolled cross wedge rolling[J]. International Jour-nal of Advanced Manufacturing Technology,2013,65:745–753.
[12]杨艳慧,刘东,贺子延,等.基于响应面法(RSM)的锻造预成形多目标优化设计[J].稀有金属材料与工程,2009,38(6):1019-1024.Yang Y H,Liu D,He Z Y,et al. Multi-objective preform optimi-zation using RSM[J]. Rare Metal Materials and Engineering,2009,38(6):1019-1024.