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针对曲轴锻件材料利用率较低的现状,以某微车四拐曲轴为例,采用带阻力墙结构的模具来提高材料利用率。运用有限元分析软件Deform3D对预锻及终锻过程进行模拟。针对终锻载荷过大问题,将终锻模具阻力墙优化为分段式阻力墙结构,有效地降低了成形载荷。同时,对各方案的模具磨损进行了分析。实际生产表明:带阻力墙结构的锻模所生产的曲轴锻件质量良好、填充饱满,材料利用率由75.9%提高到83.3%,同时成形载荷适中。
Aiming at the low utilization rate of crankshaft forgings, a four-crank crankshaft of a mini-car is taken as an example, and a mold with a resistance wall structure is adopted to improve material utilization. The finite element analysis software Deform3D was used to simulate the pre-forging and final-forging processes. For the final forging load is too large, the final forging mold resistance wall is optimized for the segmented resistance wall structure, effectively reducing the forming load. At the same time, the die wear of each program was analyzed. The actual production shows that the crankshaft forging produced by the die with the resistance wall structure is of good quality and full of filling, the material utilization rate is increased from 75.9% to 83.3% and the forming load is moderate.