锻压技术

基于DEFORM的重型汽车前轴成形工艺及模具设计

英文标题：Forming process and die design for heavy duty truck front axle based on DEFORM

作者：朱帅奚建胜

单位：湖北汽车工业学院

分类号：TG316

出版年,卷(期):页码：2021,46(5):194-200

摘要：

针对重型汽车前轴复杂的结构特征，结合金属塑性成形理论，制定了某重型汽车前轴的辊锻制坯+模锻成形的成形工艺，通过计算确定了坯料尺寸和辊锻道次，并且选取合理的前滑值，设计了辊锻工序件和辊锻型槽；采用UG三维参数化建模软件完成了辊锻模具、压弯模具、预锻模具及终锻模具的设计。并采用有限元软件Deform-3D对前轴成形工艺进行数值模拟，通过观察在前轴成形工艺中各特征部位的充型情况，及成形过程中压力、温度的变化，并对成形后前轴锻件与实际生产前轴锻件的尺寸进行对比，验证了前轴成形工艺及模具设计的合理性，缩短了模具调试周期，提高了产品的设计效率，提高了材料利用率，降低了产品开发成本。所设计的前轴成形工艺和模具已应用于实际生产。

For the complex structure characteristics of heavy-duty truck front axle, combined with the theory of metal plastic forming, the forming process of roll forging billet and die forging for the heavy-duty truck front axle was developed, and the billet sizes and the number of roll forging passes were determined by calculation. According to the reasonable forward slip value, the roll forging parts and the roll forging groove were designed, and the design of roll forging mold, bending mold, pre-forging mold and final forging mold were completed by three-dimensional parametric modeling software UG respectively. In addition, the forming process of front axle was simulated numerically by finite element software Deform-3D, and by observing the filling situation of each characteristic part in the forming process of front axle, the pressure and temperature changes during the forming process and the size comparison between the front axle forgings after forming and the actual produced front axle forgings, the rationality of forming process and mold design was verified to reduce the mold debugging period, improve the efficiency of product design and the material utilization rate, and reduce the product development cost. Finally, the designed forming process and mold for front axle were used in the actual production.

基金项目：

重型汽车前轴精确锻造技术的研发与应用（2015BAA041）

朱帅（1992-），男，硕士研究生 E-mail：1229779382@qq.com 通讯作者：奚建胜（1971-），男，硕士,教授 E-mail：xijiansheng@qq.com

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