锻压技术

铝合金汽车前下摆臂成形工艺的有限元模拟与优化

英文标题：Finite element simulation and optimization on forming process of automobile front lower sway arm for aluminum alloy

作者：殷剑黎诚金康殷佳健孙奋丽

单位：北京机电研究所有限公司中机精密成形产业技术研究院（安徽）股份有限公司

关键词：铝合金汽车前下摆臂弯曲折叠缺陷模具优化

分类号：TG316

出版年,卷(期):页码：2021,46(11):74-82

摘要：

针对6082铝合金汽车前下摆臂生产过程中发现的锻件肋部金属汇流缺陷，根据实际生产中的锻造工艺方案与模具建立有限元模型，并设置锻件的初始温度为500 ℃、摩擦因数为0.4、模具温度为280 ℃、热交换系数为2 N·（mm·s·℃）-1，然后对锻造过程进行数值模拟。并对弯曲工序与终锻工序中的温度场、压力场、零件厚度尺寸分布等进行了分析，重点研究了金属汇流缺陷处的金属流动规律，确定了其为折叠缺陷，并提出对模具过渡圆角进行优化的改进措施，将筋和腹板上圆角半径由原来的3 mm增加到8 mm。最后，通过实验验证了该模具优化措施的可行性。

For the metal confluence defect at the rib of forgings found in the production process of automobile front lower arm for 6082 aluminum alloy, a finite element model was established based on the forging process scheme and mold in the actual production, and the forging process was simulated numerically in the condition of the initial temperature of 500 ℃, the friction coefficient of 0.4, the mold temperature of 280 ℃ and the heat exchange coefficient of 2 N·（mm·s·℃）-1. Then, the distributions of temperature field, pressure field and thickness sizes of part in the bending and final forging processes were analyzed. Especially the metal flow law at the metal confluence defect was studied, and it was determined that it was a folding defect. Furthermore, the improvement measures for optimizing the transition fillet of mold were proposed, and the fillet radii of ribs and webs were increased from the original 3 mm to 8 mm. Finally, the feasibility of the mold optimization measures was verified by experiments.

基金项目：

作者简介：殷剑（1997-），男，硕士研究生，E-mail：a18726451924@163.com；通信作者：金康（1978-），男，硕士，高级工程师，E-mail：jinkang@cmipf.com

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