连皮结构对曲轴模锻成形的影响
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摘要
为提高材料利用率和锻件填充效果,利用Deform软件对曲轴模锻成形过程进行数值模拟,以曲轴平衡块顶部的充填能力作为考核指标,分析了不同厚度的平底连皮对曲轴平衡块顶部充填的影响。模拟结果表明,当连皮厚度为20 mm时,充填效果最好。并在此基础上,提出了一种凸形连皮的新结构,结合分析结果给出了两种优化方案,即降低连皮与曲轴连接部分的厚度和尽可能提高水平激烈流动停止时连皮处储存的可利用材料,并对优化方案进行了验证。结果表明,在降低冲除连皮压力、曲轴变形或产生裂纹风险的前提下,该结构可以确保曲轴平衡块顶部的饱满充填。
In order to improve the utilization of materials and the filling effect of forgings,Deform software was used to simulate the crankshaft die-forging forming process,the filling capacity of the top of the crankshaft balance block was taken as the evaluation index,the influence of wad with of flat profile different thickness on top filling of crankshaft balance block was analyzed. The simulation results show that the filling effect is the best when the thickness of the wad is 20 mm. On this basis,a new structure of wad with convex profile was proposed. Combined with the analysis results,two optimization schemes were presented,that was to reduce the thickness of the connecting part of the wad and the crankshaft and improve the available materials stored at the wad when the horizontal intense flow stops,and the optimization scheme was verified. The results show that on the premise of reducing the impact pressure,crankshaft deformation or crack risk,the structure can ensure full filling of the top of the crankshaft balance block.
In order to improve the utilization of materials and the filling effect of forgings,Deform software was used to simulate the crankshaft die-forging forming process,the filling capacity of the top of the crankshaft balance block was taken as the evaluation index,the influence of wad with of flat profile different thickness on top filling of crankshaft balance block was analyzed. The simulation results show that the filling effect is the best when the thickness of the wad is 20 mm. On this basis,a new structure of wad with convex profile was proposed. Combined with the analysis results,two optimization schemes were presented,that was to reduce the thickness of the connecting part of the wad and the crankshaft and improve the available materials stored at the wad when the horizontal intense flow stops,and the optimization scheme was verified. The results show that on the premise of reducing the impact pressure,crankshaft deformation or crack risk,the structure can ensure full filling of the top of the crankshaft balance block.
引文
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[2]王梦寒,汪丰林,李晶.多拐曲轴模锻成形毛坯精化技术[J].热加工工艺,2009,38(23):105-108.WANG Menghan,WANG Fenglin,LI Jing. Billet optimization of die forging for several cylinder sleeve crankshaft[J]. Hot Working Technology,2009,38(23):105-108.
[3]吕炎.锻造工艺学[M].北京:机械工业出版社,1995.LYan. Forging technology[M]. Beijing:China Machine Press,1995.
[4]夏巨谌,金俊松,邓磊,等.中空分流锻造成形机理及成形力的计算[J].塑性工程学报,2016,23(1):1-6.XIA Juchen, JIN Junsong, DENG Lei, et al. Mechanism of forging utilizing flow relief hole and forming load calculation[J].Journal of Plasticity Engineering,2016,23(1):1-6.
[5]赵晨阳,李洪波,韩金成,等.花键轮精密锻造成形的数值模拟及实验研究[J].锻压技术,2016,41(1):11-15.ZHAO Chenyang,LI Hongbo,HAN Jincheng,et al. Numerical simulation and experimental research on precision forging for spline gear[J]. Forging&Stamping Technology,2016,41(1):11-15.
[6]陶善虎,刘燕波,何庆伟,等.转向弯臂锻造成形工艺改进[J].锻压技术,2016,41(1):6-19.TAO Shanhu,LIU Yanbo,HE Qingwei,et al. Forging process improvement of steering curve arm[J]. Forging&Stamping Technology,2016,41(1):6-19.
[7]江学强,吉卫,曹海桥,等. DT4锻造开裂原因分析及控制措施研究[J].锻压技术,2015,40(6):116-120.JIANG Xueqiang,JI Wei,CAO Haiqiao,et al. Research on the crack mechanism and crack control measures of hot forging solenoid DT4[J]. Forging&Stamping Technology,2015,40(6):116-120.
[8]韩琦,李志广,李萌.模锻件复合式冲孔连皮结构优化设计[J].金属加工(热加工),2013,(11):61-63.HAN Qi,LI Zhiguang,LI Meng. Optimization design of composite punch wad structure of modular forgings parts[J]. MW Metal Forming,2013,(11):61-63.
[9]李路.重车转向节复合成形新工艺关键技术-挤压工艺性及挤压模具寿命研究[D].重庆:重庆大学,2010.LI Lu. Study on the extrusion process and extrusion die life for knuckle of heavy truck compound process[D]. Chongqing:Chongqing University,2010.