锻压技术

某铝合金复杂锻件成形工艺设计及DEFORM3D模拟优化

英文标题：Forming process design and DEFORM3D simulation optimization for a complex aluminum alloy forging

单位：（1.中国科学院金属研究所辽宁沈阳110016 2.中国科学技术大学材料科学与工程学院安徽合肥230026）

分类号：TG316

出版年,卷(期):页码：2018,43(5):0-0

摘要：

为了满足轨道车辆某受力构件以铝代钢的轻量化要求，对某铝合金锻件成形工艺展开研究，并结合DEFORM3D有限元模拟分析进行优化设计，最终获得合格产品，与原铸钢件相比，重量减轻65%。该锻件外形为较复杂的非对称结构，锻造成形过程存在金属流动不均匀、成形不完整、所需压力大等问题，采取数值模拟方法对该锻件在成形过程中出现的问题进行分析，在保证一定的成形压力条件下，通过合理设计模具及飞边槽结构，优化锻坯外形及尺寸，改善了变形过程中金属流动方向和型腔填充模式。通过生产试验获得表面质量良好、力学性能合格的锻件，为此类锻件的生产制备提供了借鉴。

In order to meet the requirements of “lightweight” and “replace steel with aluminum” for a component of railway vehicle, the forming process of a aluminum alloy forging was researched, and the parameters were optimized by DEFORM3D finite element simulation. Then, the qualified products were obtained, and the weight was reduced by 65% comparing with original steel castings. The problems of uneven metal flow,incomplete forming and higher forging pressure during the forging process for parts with complex asymmetric structure were analyzed by numerical simulation, and the metal flow direction and cavity filling mode in deformation process were improved by reasonable design of mould and flash groove structure and optimizing the shape and size of blank. Finally,the forgings with good surface quality and mechanical properties were obtained by production tests which provided a reference for the production of this kind of forgings.

基金项目：

沈阳市重点科技研发计划项目（17-32-6-00）

作者简介：王松伟（1990-），男，博士研究生 Email：swwang16b@imr.ac.cn 通讯作者：张士宏（1962-），男，博士，教授 Email：shzhang@imr.ac.cn

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