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铝合金汽车支架热锻缺陷分析及模具优化
英文标题:Analysis on hot forging defects of aluminum alloy automobile brackets and mould optimization
作者:吕弘毅 龚红英 缪军 张杰 
单位:上海工程技术大学 
关键词:6061铝合金 汽车发动机支架 热锻缺陷 模具优化 Deform-3D 
分类号:TG319
出版年,卷(期):页码:2018,43(1):117-123
摘要:

为消除铝合金汽车发动机支架在热锻过程中所产生的折叠、充不满、起皮、表层剥离等各种缺陷,基于Deform-3D对6061铝合金汽车支架热锻成形过程进行了有限元模拟,发现缺陷产生的原因为预锻成形过程中金属流线紊乱、金属流动速度不均以及拐角处有多股金属汇流。针对缺陷产生的原因,提出了3种模具优化方案并分别进行模拟,对比分析了3种方案的锻造缺陷、金属充型效果和锻造载荷。结果表明,方案2和方案3成形结果良好,但相比方案2而言,方案3不需要改变预锻模具,故减少了加工成本且方案3的锻造载荷比方案2小1970 kN。所以,确认方案3为最优方案,并在压力机上进行小批量的生产验证,其生产结果与模拟结果相一致。

In order to eliminate defects of folding, insufficient filling, peeling, skin peel off produced in the hot forging process of aluminum alloy automobile engine brackets, the hot forging process of aluminum alloy 6061 for automobile brackets was numerically simulated by Deform-3D, and the reasons of defects were disturbances of metal flow lines, unsteady metal flow rates and multiple metal confluence at corners during the pre-forging process. According to the above reasons of defects, three kinds of molud optimization schemes were proposed and simulated separately, and the forging defects, metal filling effect and forging load were compared. The results show that the forming results of scheme 2 and scheme 3 are both good. However, compared with scheme 2, scheme 3 does not need to change the pre-forging mould to reduce the processing cost, and the forging load of scheme 3 is 1970 kN less than that of scheme 2. Therefore, scheme 3 is regarded as the best. Furthermore, the small batch production was produced on the press, and the production results and simulation results were consistent.

基金项目:
2017年上海市研究生课程建设项目(A1-8944-17-0303);“基于材料科学与工程一级学科的研究生课程建设”校企合作项目(157CL-027;177CL-001)
作者简介:
作者简介:吕弘毅(1989-),男,硕士研究生,E-mail:lvhongyi89@sina.com;通讯作者:龚红英(1974-),女,工学博士,硕士生导师,教授,E-mail:ghyyw1974@163.com
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