汽车弯臂锻件多道次锻造成形工艺研究及数值模拟
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摘要
汽车弯臂零件是汽车的保全件之一,在汽车运行中实现承载、导向功能,其工作运行环境比较复杂,使用的安全可靠性能要求也非常高。汽车弯臂零件传统的锻造工艺设计主要依靠经验进行试错设计,由于不能明确锻造过程中金属在模具中的流动情况,常造成坯料设计不合理导致锻件存在折纹、缺肉等缺陷,模具寿命低。随着计算机技术和数值计算方法的发展,以有限元法为代表的数值模拟技术被广泛的应用于分析金属塑性成形过程。
本文根据热锻成形理论,以HF6700轻卡汽车弯臂为研究对象,主要研究内容如下：
1.通过分析弯臂锻件结构特点,结合原有工艺提出了辊锻——摩擦压力机模锻的工艺,即下料→中频感应炉加热→辊锻制坯→630t摩擦压力机弯曲→1000t摩擦压力机终锻→热切边→热校正的成形工艺。
2.利用有限元模拟软件,对弯臂锻件多道次锻造成形建立了三维热力耦合有限元模型,并进行了有限元模拟分析。通过模拟得到合理的制坯形状和尺寸,辊锻、预弯、终锻的金属流动分布等,为模具的设计和实际生产操作提供了依据和参考。
3.基于Archard磨损模型,研究了终锻成形时模具预热温度T预热,摩擦因子m和模具初始硬度HRC对模具磨损量w的影响规律,并对终锻模具的模具寿命进行了预测。
Automotive steering knuckle arm is one of the safety parts, which to achieve load and guidance functions in the car is running. Their work more complex operating environment, the use of security and reliability requirements can be very high. The traditional forging process design mainly rely on the experiences of trial and error design, the lack of a clear steering knuckle arm forging metal in the process of the flow in the mold, often caused by an unsuitable design billets, forgings there folding patterns, lack of meat and other defects, low die life. With the computer technology and numerical calculation methods development, as represented by the finite element method numerical simulation technique has been widely used in analysis of metal forming processes.
In the paper, based on the hot forging forming theory, take HF6700 steering knuckle arm of light truck as the research object, the main research contents are as follows:
1. By analyzing the structural characteristics of steering knuckle arm forging, combined with the original technique proposed roll forging-friction press forging process, that is, baiting→medium-frequency induction furnace heating→Roll forging billet (2 times)→630t friction screw press bending→1000t friction screw press for the final forging→hot side cut→hot correction.
2. Using finite element simulation software, established a three-dimensional coupled thermo-mechanical model and taken the finite element simulation for multi-pass forging process of steering knuckle arm. Through simulation and optimization of the system blank of blank shape and size, obtain the metal flow distribution of roll forging, pre-bend, and finally forging, analysis of each pass of the strain field, stress field, velocity field and forming load and so on, for mold design and the actual manufacturing operations provides the basis and reference.
3. Based on the Archard wear model, research the law of the final forging die when the preheating temperature Tpre, friction factor m and the initial die hardness of HRC on the influence of the amount of die wearing, and predicted die life for the last forging die.
本文根据热锻成形理论,以HF6700轻卡汽车弯臂为研究对象,主要研究内容如下：
1.通过分析弯臂锻件结构特点,结合原有工艺提出了辊锻——摩擦压力机模锻的工艺,即下料→中频感应炉加热→辊锻制坯→630t摩擦压力机弯曲→1000t摩擦压力机终锻→热切边→热校正的成形工艺。
2.利用有限元模拟软件,对弯臂锻件多道次锻造成形建立了三维热力耦合有限元模型,并进行了有限元模拟分析。通过模拟得到合理的制坯形状和尺寸,辊锻、预弯、终锻的金属流动分布等,为模具的设计和实际生产操作提供了依据和参考。
3.基于Archard磨损模型,研究了终锻成形时模具预热温度T预热,摩擦因子m和模具初始硬度HRC对模具磨损量w的影响规律,并对终锻模具的模具寿命进行了预测。
Automotive steering knuckle arm is one of the safety parts, which to achieve load and guidance functions in the car is running. Their work more complex operating environment, the use of security and reliability requirements can be very high. The traditional forging process design mainly rely on the experiences of trial and error design, the lack of a clear steering knuckle arm forging metal in the process of the flow in the mold, often caused by an unsuitable design billets, forgings there folding patterns, lack of meat and other defects, low die life. With the computer technology and numerical calculation methods development, as represented by the finite element method numerical simulation technique has been widely used in analysis of metal forming processes.
In the paper, based on the hot forging forming theory, take HF6700 steering knuckle arm of light truck as the research object, the main research contents are as follows:
1. By analyzing the structural characteristics of steering knuckle arm forging, combined with the original technique proposed roll forging-friction press forging process, that is, baiting→medium-frequency induction furnace heating→Roll forging billet (2 times)→630t friction screw press bending→1000t friction screw press for the final forging→hot side cut→hot correction.
2. Using finite element simulation software, established a three-dimensional coupled thermo-mechanical model and taken the finite element simulation for multi-pass forging process of steering knuckle arm. Through simulation and optimization of the system blank of blank shape and size, obtain the metal flow distribution of roll forging, pre-bend, and finally forging, analysis of each pass of the strain field, stress field, velocity field and forming load and so on, for mold design and the actual manufacturing operations provides the basis and reference.
3. Based on the Archard wear model, research the law of the final forging die when the preheating temperature Tpre, friction factor m and the initial die hardness of HRC on the influence of the amount of die wearing, and predicted die life for the last forging die.
引文
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[2]金明华,陈庆敏,寇淑清,金文明.复杂弯轴类锻件辊锻—摩擦压力机模锻复合锻造工艺[J].锻压技术,1999,4：12-14
[3]高占民,杨慎华.轻卡车左转向节臂锻造工艺分析[J].材料.工艺.设备,1999,8：23-24
[4]唐新民,陈建业,赵九根,敖红专.非调质钢弯臂、直臂的开发应用[J].金属热处理,2001,1：43-45
[5]邓春萍,杨慎华,何东野.汽车左转向节臂锻件复合锻造工艺及模具设计[J].锻造,2006,3：42-44
[6]吴淑玲等.6400转向节臂成形分析及有限元模拟[J].模具技术,2004,4：10-11,30
[7]孙前江,王高潮,黄映霞,李宁.曲轴锻造过程的数值模拟[J].锻压技术,2006,2：4-6
[8]王延强,王若平,林军.某型汽车转向节臂断裂原因分析[J].机械设计与制造,2007,6：126-127
[9]龙丽.TA15合金锻造过程的数值模拟[D].西北工业大学硕士学位论文,2005
[10]C.H.Lee, S.Kobayashi. New Solution to Rigid-Plastic Deformation Problems Using a Matrix Method [J]. Trans.ASME.J,Engr.Ind,1973,95:871-873
[11]O.C.Zienkiewiez, P.N.Godbole. A penalty Function Approach to Problems of Plastic Flow of Metals with Large surface Deformations [J]. J.Strain.Analysis, 1975,10:180-196
[12]S.Kobayashi, S.I.Oh, T.Altan. Metal Forming and the Finite Element Method [M]. Oxford University Press, London,1989
[13]S.I.Oh. Finite Element Analysis of Metal Forming Processes with Arbitrarily Shaped Dies [J]. International Journal of Mechanical Sciences,1982,24(8): 479-488
[14]J.J.Park, S.Kobayshi. Three-dimension Finite Element Analysis of Block Compression [J]. International Journal of Mechanical Sciences,1984,26(3): 165-176
[15]J.H.Yoon, D.Y.Yang. Rigid-Plastic Finite Element Analysis of Three-Dimensional Forging by Considering Friction on Continuous Curved Dies With Initial Guess Generation [J]. International Journal of Mechanical Sciences,1988,30:887-898
[16]V.Vazquez, T.Altan. Die design for fleshless forging of complex parts [J]. Journal of Materials Processing Technology,2000.98:81-89
[17]王忠金.模锻过程的三维模拟及连杆终锻成形规律的研究[D].吉林工业大学硕士学位论文,1995
[18]卫原平,彭颗红,阮雪榆.金属塑性成形过程的计算机模拟系统[J].上海交通大学学报,1996,3：132-137
[19]蒋浩民.锻造过程三维数值模拟系统H-FORGE3D的开发与应用[D].哈尔滨工业大学博士学位论文,1998
[20]蒋鹏,方刚等.汽车前轴精密辊锻成形过程的数值模拟[J].机械工程学报,2005,41(6)：123-127
[21]程联军,赵国群等.有限元模拟在后轴支架锻造设计中的应用[J],塑性工程学报,2008,15(1)：15-17
[22]陈文琳,朱玉生等.半轴套管热挤压成形工艺数值模拟[J].农业机械学报,2007,38(11)：152-156
[23]王荐.转向节挤压制坯过程工艺设计及数值模拟.合肥工业大学硕士论文,2009
[24]B.Painter, R.Shivpur, I.T.Altan. Predictions of die wear during hot-extrusion of engine valves [J]. Journal of Materials Processing Technology,1996,59: 132-143
[25]R.S.Lee, J.L.Jou. Application of numerical simulation for wear analysis of warm forging dies [J]. Journal of Materials Processing Technology,2003,140: 43-48
[26]O.Barrau, C.Boher, R.Gras, F.Rezai-Aria. Analysis of the friction and wear behaviour of hot work tool steel for forging [J]. Wear,2003,255:1444-1454
[27]B.-A.Behrens, F.Schaefer. Prediction of wear in hot forging tools by means of finite-element-analysis [J]. Journal of Materials of Processing Technology, 2005,167:309-315
[28]B.-A.Behrens. Finite element analysis of die wears in hot forging [J]. CIRP Annals-Manufacturing Technology,2008,57:305-308
[29]王雷刚,黄瑶,孙宪萍等.基于修正Archard磨损理论的挤压模具磨损分析[J].润滑与密封,2006,3：10-12
[30]黄瑶,孙宪平,王雷刚等.基于BP神经网络的挤压模具磨损预测[J].塑性工程学报,2006,13(2)：64-66
[31]周杰,赵军,安治国.热挤压模磨损规律及磨损对模具寿命的影响[J].中国机械工程,2007,18(17)：2112-2115
[32]汪学阳,王华君,王华昌等.基于FEM的热锻模磨损分析与寿命预测[J].润滑与密封,2008,33(5)：49-53
[33]J.T.Oden, D.R.Bhandari, et al. A New Approach to the Finite Element Formulation and Solution of a Class of Problems in Coupled Thermoplastic visco-Plasticity of Crystalline Solids [J]. Nuelear.Engng.Des,1973,24: 420-435
[34]O.C.Zienkiewiez, E.Onateetal. A General Formulation for Coupled Thermal Flow of Metals Using Finite Elements [J]. Int.J.Num.Meth.Engng,1981,17: 1497-1514
[35]N.Rebelo, S.Kobayashi. A Coupled Analysis of Viscoplastic Deformation and Heat Transfer [J]. Int.J.of Mech.Sci,1980,22:688-705
[36]N.Soyris, J.J.Brioist. Three Dimensional Finite Element Calculation of the Whole Forging Process of an Automotive Part [J]. Proe.the 3rd ICTP, Tokyo, Japan,1990,165-170
[37]S.Shamasundar, A.A.Tsengetal. Numerical and Experimental Study of the Thermal Behavior of Coining and Upsetting processes [J]. Journal of Materials processing Technology,1993,36(2):199-221
[38]詹艳然,王仲仁.塑性成形数值模拟中温度边界条件的处理[J].塑性工程学报,2001,1：4-7
[39]崔荣荣.汽车转向节锻造工艺及有限元模拟研究[D].山东大学硕士学位论文,2008
[40]牟正君.航空零件和重型燃机叶片锻造过程数值模拟[D].大连理工大学硕士学位论文,2005
[41]张清萍.齿轮精锻过程三维数值模拟及关键工艺技术研究[D].山东大学博士学位论文,2004
[42]陈如欣,胡忠民.塑性有限元法及其在金属成形中的应用[M].重庆：重庆大学出版社,1989
[43]汪磊.钢活塞锻造过程的数值模拟分析[D].上海交通大学硕士学位论文,2008
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