锻压技术

汽车前轴第1道次辊锻成形工艺有限元模拟与实验

英文标题：Finite element simulation and experimental research on the automobile front axle beam in the preliminary roll forging process

作者：吕霄刘艳雄王孝文

单位：武汉理工大学

关键词：汽车前轴辊锻成形 Deform-3D 辊锻角速度前轴锻件

分类号：TG316

出版年,卷(期):页码：2017,42(2):5-11

摘要：

建立了前轴辊锻第1道次模型，并利用Deform-3D软件进行模拟仿真，通过与实际辊锻成形前轴进行对比，确定了合理的边界条件，并对其准确性进行了验证。由分析可知，摩擦因子为0.6、传热系数为11时，模拟结果与实验结果对比误差最小。研究了传热系数、摩擦因子、初始温度、辊锻角速度、模具板簧处圆角等工艺参数对辊锻第1道次成形的影响规律。结果表明，摩擦因子增大和初始温度升高，锻件弹簧板中心距和最大展宽均随之增大。转动角速度增大，弹簧板中心距、最大展宽逐渐减小。锻件总长和最大展宽随着模具板簧处圆角增大而减小。通过第1道次辊锻制坯工艺优化，降低了终锻成形载荷，提高了终锻模具型腔填充程度与材料利用率。

A 3D finite element (FE) model of the preliminary roll forging process for the automobile front axle was established, and the numerical simulation was conducted by the Deform-3D platform. Then, a reasonable boundary condition was confirmed by comparing the simulation result with actual roll forging of front axle, and its accuracy was verified. The analysis shows that the error between the simulation and experimental results is the smallest with friction factor of 0.6 and heat transfer coefficient of 11. It was analyzed the influences of the heat transfer coefficient, friction factor, initial temperature of billet, rotational speed of roll forging, die fillet of spring on the preliminary roll forging process of automobile front axle beam. The results show that when the friction factor and the initial temperature increase, the center distance of spring and the maximum width increase. As the rotational speed increases, the center distance of spring and the maximum width gradually decrease. The general forging length and the maximum width decrease with the increase of die fillet. Thus, through the optimization of the preliminary roll forging process, the final forging load is reduced, and the utilization ratio of material is improved.

基金项目：

基金项目:教育部创新团队发展计划项目（IRT13087）

吕霄（1992-），男，硕士研究生刘艳雄（1985-），男，博士，副教授

参考文献：

［1］王洪强. 重载汽车前轴成形工艺研究[D]. 重庆：重庆理工大学，2012.Wang H Q. Study on Forming Process of Heavy Automobile Front Axle[D].Chongqing: Chongqing University of Technology，2012.
［2］田平, 彭成允, 邹强. 大变截面连杆辊锻制坯工艺技术发展现状[J]. 精密成形工程, 2010, 2(2):65-68.Tian P, Peng C Y, Zou Q. The development status on the technology of whole roll forging billets′ making of connecting rod of different sections [J]. Journal of Netshape Forming Engineering, 2010, 2(2):65-68.
［3］李如雄，王金铝. 汽车前轴制坯辊锻工艺分析与模具设计[J]. 机械设计与制造, 2010，(10):243-245.Li R X, Wang J L. Blank-making roll-forging process and die design for automotive front axle [J]. Machinery Design & Manufacture, 2010，(10):243-245.
［4］信昆峰. 轴类零件辊锻制坯工艺研究与模具设计[D]. 武汉：武汉理工大学, 2011.Xin K F. The Roll-Forging Making Billets Process Research and Mould Design of Shaft Forgings [D]. Wuhan: Wuhan University of Technology, 2011.
［5］周杰, 柳豪, 刘旭光,等. 某重型卡车前轴成形辊锻工艺设计与优化[J]. 重庆大学学报, 2012, 35(3):67-73.Zhou J, Liu H, Liu X G, et al. Design and optimization of the precision roll forging on a heavy truck front axle [J]. Journal of Chongqing University, 2012, 35(3):67-73.
［6］文琍, 刘旭光, 张黎,等. 某重卡前轴成形辊锻数值模拟刮料缺陷分析[J]. 热加工工艺, 2012, 41(7):95-97.Wen L, Liu X G, Zhang L, et al. Analysis for scrapings defects in forming roll-forging process of a front axle of heavy truck[J]. Hot Working Technology, 2012, 41(7):95-97.
［7］Li R X，Jiao S H，Wang J L. Roll-forging technology of automotive front axle precision performing and die design [J]. Ieri Procedia, 2012，1(1):166-171.
［8］Zhuang W, Hua L, Wang X, et al. Numerical and experimental investigation of roll-forging of automotive front axle beam [J]. International Journal of Advanced Manufacturing Technology, 2015, 79(9-12):1-17.
［9］Zhuang W, Hua L, Wang X, et al. The influences of process parameters on the preliminary roll-forging process of the AISI-1045 automobile front axle beam [J]. Journal of Mechanical Science & Technology, 2016, 30(2):837-846.
［10］魏科，王高潮，李宁，等. 基于DEFORM和正交试验法的前轴辊锻工艺优化[J]. 塑性工程学报，2012，19(1):6-10.Wei K, Wang G C, Li N, et al. Research on optimization of front axle roll forging technique based on DEFORM-3D and orthogonal experimental method[J]. Journal of Plasticity Engineering，2012，19(1):6-10.
［11］柳豪，周杰，万煦义，等. 某重卡前轴成形辊锻质量因素分析[J]. 金属铸锻焊技术，2010，39(21):107-108.Liu H, Zhou J, Wan X Y, et al. Analysis on quality factors of precision roll-forging of a heavy truck′s front axle [J]. Casting Forging Welding, 2010，39(21):107-108.
［12］周杰，潘成海，黎燕，等. 基于RSM和FEM的辊锻件长度控制技术[J]. 华中科技大学学报:自然科学版， 2014,42(2):68-73.Zhou J, Pan C H, Li Y, et al. Technology of controlling the length of precision roll forgings based on RSM and FEM [J]. Journal of Huazhong University of Science and Technology：Natural Science Edition, 2014,42(2):68-73.
［13］Lu C，Tieu A K. Measurement of the forward slip in cold strip rolling using a high speed digital camera [J]. Journal of Mechanical Science & Technology，2007，21(10):1528-1533.

服务与反馈：

【文章下载】【加入收藏】