锻压技术

高压共轨锻件预制坯的形状优化设计

英文标题：Optimization design on shape of preform for high pressure common rail forgings

单位：1.山东大学材料液固结构演变与加工教育部重点实验室 2.金马工业集团股份有限公司

分类号：TG316

出版年,卷(期):页码：2021,46(12):1-5

摘要：

为了提高材料的利用率，对Q4041高压共轨锻件预制坯的形状进行了优化设计。根据实际生产中终锻件中间部位飞边量较大的情况，设计了哑铃型预制坯形状，提出了采用辊锻制坯代替现有制坯的工艺方法。设计了4种不同形状的预制坯形状，采用有限元软件对设计的预制坯进行了锻造过程模拟。采用机加工方式制备了预制坯，进行了实际的锻造实验，并与模拟结果进行对比，确定了4种辊锻预制坯方案中能够完全充满型腔且飞边量最小的预制坯形状。实验结果表明，有限元模拟结果与实际的锻造过程相一致，采用优化的预制坯进行锻造生产可以减少35%的飞边，因此，采用辊锻制坯工艺是可行的。

In order to improve the utilization rate of materials, the shape of preform for Q4041 high pressure common rail forgings was optimized and designed. Then, according to the large amount of flash in the middle part of final forgings in actual production, the shape of dumbbell preforms was designed, and the process method of using roll forging preform to replace the existing preform was proposed. Furthermore, four different shapes of preform were designed, and the forging process of preforms was simulated by finite element software. Finally, the preform was fabricated by machining, and the actual forging experiment was carried out. Compared with the simulation results, the preform shape which completely filled the cavity and had the least flash in the four roll forging preform schemes was determined. The experimental results show that the results of finite element simulation are consistent with those of the actual forging process, and the flash is reduced with 35% with the optimized preform in the forging production. Thus, the preform process by the roll forging is feasible.

基金项目：

山东省重大科技创新工程项目（2019JZZY010431）；日照市重大科技专项计划（2020CXZX1207）

马新武(1975-)，男，博士，教授 E-mail：maxinwu@sdu.edu.cn 通信作者：赵国群(1962-)，男，博士，教授

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