锻压技术

气门电镦成形数值模拟及工艺优化

英文标题：Numerical simulation and process optimization on valve electric upsetting

作者：陈磊王宗申崔来胜朱立华

分类号：TG316

出版年,卷(期):页码：2020,45(7):13-21

摘要：

利用DEFORM-3D建立汽车发动机气门电镦工艺的有限元模型，对气门电镦成形过程进行数值模拟，分析变形过程中的金属流动规律以及坯料温度、等效应变和晶粒尺寸的分布情况。结果表明，电镦件的平均晶粒尺寸大且分布不均匀，“蒜头”高温区与杆部冷料区过渡部分的金属流动变化大，等效应变分布不均匀。通过响应曲面法和遗传算法优化，获得当电镦温度为1053 ℃、电镦速度为1.2 mm·s-1和夹持长度为7.25 mm时，电镦件的平均晶粒尺寸最小，约为7.3 μm。对优化前、后的气门电镦及模锻过程进行模拟分析。最终，气门锻件的最大晶粒尺寸由27.0 μm降至14.4 μm，平均晶粒尺寸也由12.1 μm 减小至7.76 μm，晶粒细化效果显著。同时，模拟预测结果与气门锻件的金相实验观察结果基本一致，从而验证有限元模型及优化过程的合理性与可靠性，为气门锻件的实际生产提供指导。

The finite element model of electric upsetting process for automobile engine valve was established by DEFORM-3D. Then, the electric upsetting process of valve was numerically simulated, and the metal flow rules and the distributions of billet temperature, equivalent strain and grain size during the deformation process were analyzed. The results show that the average grain size of electric upsetting part is large and distributes heterogeneously, the metal flow in the transition section between the high temperature region of head and the cold temperature region of stem varies obviously and its equivalent strain distribution is inhomogeneous. Through response surface method and genetic algorithm optimization, the minimum average grain size of electric upsetting part is about 7.3 μm when the electric upsetting temperature is 1053 ℃, the electric upsetting speed is 1.2 mm·s-1 and the clamping length is 7.25 mm. The valve electric upsetting process and the die forging process before and after optimization were simulated and analyzed. Finally, the maximum grain size of valve forging is reduced from 27.0 to 14.4 μm, and the average grain size is also decreased from 12.1 to 7.76 μm which indicates significant grain refinement effect. Meanwhile, the simulated prediction results are basically consistent with the metallographic experimental observation results of valve forging, and the reasonability and reliability of finite element model and optimization procedure are verified to provide guidance for the practical production of valve forging.

基金项目：

淄博市校城融合发展计划项目（2018ZBXC037）

陈磊（1997-），男，硕士研究生 E-mail：gtchenlei@163.com 通讯简介：王宗申（1986-），男，博士，讲师 E-mail：wangzsh@sdut.edu.cn

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