目的 以一种多阶梯双通连接接头为研究对象,解决热锻成形过程中存在的成形不饱满、冲孔不完全、尺寸精度低等问题。方法 采用有限元方法进行数值仿真实验,利用Deform-3D软件模拟了多工位热锻成形方案的锻件金属流动过程与温度演化,分析了锻件的型腔填充完整度、成形载荷的峰值变化趋势、等效应力应变的分布均匀性以及锻件的截面温差,开展了多工位方案模具设计与试模生产。结果 在多工位成形方案下,锻件表面节点分布均匀,金属流动正常,无折叠等不良缺陷,模具内部无填充不足情况;多工位成形载荷增长稳定,无应力应变突变,锻件温差在合理范围内,最终锻件能达到外形尺寸要求。对多工位进行试模生产发现,在试模生产中,锻件成形良好、填充饱满、冲孔明显,尺寸精度满足要求。结论 对于多阶梯双通连接接头,采用多工位热锻工艺可有效解决多阶梯双通连接接头的成形缺陷问题,仿真与实验的相互印证,证明了该工艺方案的可行性与可靠性,为同类复杂结构件的精密锻造提供了参考。
Abstract
The work aims to select a multi-step double-pass connecting joint as the research object to address the issues of incomplete forming, insufficient punching, and low dimensional accuracy in the hot forging process. Numerical simulation experiments were conducted with the finite element method. The multi-station hot forging process was simulated with Deform-3D software to investigate the metal flow behavior and temperature evolution of the forging. The analysis focused on the filling integrity of the forging, the peak variation trend of forming load, the distribution uniformity of equivalent stress and strain, as well as the cross-sectional temperature difference of the forging. In addition, die design and trial production were carried out for the multi-station scheme. The simulation results showed that, in the multi-station forming process, the surface node distribution of the forging was uniform, metal flow was normal, and no folding or other defects occurred, with no underfilling inside the die. The forming load increased steadily without abrupt changes in stress or strain, and the temperature difference remained within a reasonable range. The final forging met the specified external dimensional requirements. In the trial production, the forgings exhibited good formability, complete die filling, clear punching, and dimensional accuracy within tolerance. For the multi-step double-pass connecting joint, the multi-station forming process effectively avoids forging defects. The feasibility and reliability of applying the multi-station hot forging process to the multi-step double-pass connecting joint are verified through both simulation and experimental results, providing a reference for the precision forging of similar complex structural components.
关键词
多阶梯双通连接接头 /
精锻成形工艺 /
多工位设计 /
塑性成形仿真 /
模具设计
Key words
multi-step double-pass connecting joint /
precision forging and forming process /
multi-station design /
plastic forming simulation /
die design
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基金
2022年浙江省基础公益研究计划（LGG22E050034）
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