锻压技术

曲轴锻造过程中的金属流动分析与磁痕研究

英文标题：Metal flow analysis and study of the magnetic marks during the crankshaft forging process

作者：李爱娜骆仕斌

单位：阳江职业技术学院

关键词：六拐曲轴磁粉探伤数值模拟锻造

分类号：TG316

出版年,卷(期):页码：2015,40(12):11-15

摘要：

针对六拐曲轴进行磁粉探伤分析，观察探伤后磁痕的形貌和分布，采用三维有限元软件Transvalor Forge-3D对曲轴的热锻过程进行数值模拟，研究热锻过程中金属流动对曲轴磁痕的影响。模拟表明，在预锻和终锻过程中，第3、4拐与第1、6拐内侧分模面对应于曲轴的中心金属分布处，而中心金属的圆截面在第2、5拐截面上的横向分布为中心偏上10 mm左右。中心金属流至第1拐和第3拐的内侧圆角处，使得中心金属在经过后续的机加工等工序后，易暴露在工件表面，中心金属材料的外露易诱发裂纹、磁痕等的发生，这是磁痕形成的主要原因之一。结果表明，通过调整模具的预锻尺寸可以避免中心金属材料的暴露，严格控制原材料质量，控制中心金属的缺陷在一定允许范围内,可以避免实际锻造中曲轴内部缺陷的发生。

For six throw crankshaft, the magnetic particle inspection analysis was carried out, and the morphology and distribution of the magnetic marks were observed after the above test. Further, the forging process of crankshaft was simulated by three-dimensional finite element software Transvalor Forge-3D, and the influence of the metal flow on the crankshaft magnetic marks during forging process was studied. The simulation results show that during the pre-forging and final forging process, the inside parting surface of the third and the fourth cranks,the first and the sixth cranks corresponds to the central material, and the transverse distribution of the second and the fifth cranks in the circular section of the central material is about 10 mm above the center. Therefore, when the central material flows to the inside fillet of the first and the third cranks, it is easy to expose on the surface of the workpieces after the subsequent machining processes, and the exposed central material is easy to cause cracks and magnetic marks, which is one of the main reasons of the magnetic marks formation. The results show that the exposure of the central metal material can be avoided by adjusting the pre-forging size of the die, and the quality of the raw materials can be controlled strictly, and the defects of the central metal are limited within a certain allowable range. As a result, the internal defects of crankshaft in actual forging can be avoided.

基金项目：

河南省重点攻关项目（132102210119）；阳江职业技术学院2014年院内教改课题

作者简介：李爱娜（1977-），女，硕士研究生，讲师，工程师

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