目的 针对目前全浮式半轴制造工艺存在的锻件余量大、锻件折叠缺陷多等问题,根据某型号全浮式半轴法兰盘的结构特点,提出一种新的短流程近净成形工艺,以提高生产效率,降低生产成本。方法 首先利用高温压缩实验得到全浮式半轴法兰盘所用材料40Cr的真实应力-应变曲线,将数据导入数值模拟软件Deform-3D中,其次,对全浮式半轴法兰盘的短流程近净成形关键工艺参数进行正交实验优化,通过优化得到合理的工艺参数,并对优化后的成形过程进行有限元模拟分析,分析等效应力场分布和模具应力分布等。最后,根据数值模拟结果选择合适设备并进行模具结构设计、加工制造,并进行了相应的工艺试验验证。结果 通过优化得到全浮式半轴法兰盘聚料过程最优的工艺参数组合如下：成形温度为1 150 ℃、成形速度为20 mm/s、摩擦因数为0.3。工艺试验得到的全浮式法兰盘锻件充填饱满,尺寸满足设计要求,经过后续机械加工后,未出现锻造裂纹、折叠等缺陷。结论 本文提出的全浮式法兰盘短流程近净成形工艺是可行的,可为该类零件的现有制造工艺提供指导,且该工艺易于实现自动化生产,从而实现该类零件的绿色高效生产。
Abstract
In response to the problems of large forging allowance and folding defects in the current manufacturing process of fully floating half shafts, the work aims to propose a new short process near net forming technology based on the structural characteristics of a certain model of fully floating half shaft flange, in order to improve production efficiency and reduce production costs. Firstly, the true stress-strain curve of the material 40Cr used for the fully floating half shaft flange was obtained through high-temperature compression experiments. The data were imported into the numerical simulation software Deform-3D. Then, the key process parameters of the short process near net forming of the fully floating half shaft flange were optimized through orthogonal experiments, and reasonable process parameters were obtained through optimization. Finite element simulation analysis was conducted on the optimized forming process to analyze the equivalent stress field distribution and mold stress distribution. Finally, based on the numerical simulation results, the suitable equipment was selected and the mold structure design and manufacturing were carried out. Finally, corresponding process experiments were conducted for verification. The optimal process parameter combination for the aggregation process of the fully floating half shaft flange plate obtained through optimization was forming temperature of 1 150 ℃, forming speed of 20 mm/s, and friction coefficient of 0.3. The fully floating flange forging obtained from the process test was fully filled and met the design requirements in terms of size. After subsequent mechanical processing, there were no defects such as forging cracks or folding. The short process near net forming technology for fully floating flanges proposed is feasible and can provide guidance for the current manufacturing process of such parts. Moreover, this technology is easy to achieve automated production, thereby realizing green and efficient production of such parts.
关键词
全浮式半轴 /
近净成形 /
正交实验 /
数值模拟 /
工艺试验
Key words
fully floating half shaft /
near net forming /
orthogonal experiment /
numerical simulation /
process test
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基金
河南省高等学校重点科研项目（24B430021）
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