锻压技术

汽车突缘叉热锻模具磨损的有限元分析及验证

英文标题：Finite element analysis and verification on wear of hot forging die for automobile flange fork

作者：李禧张莹陈志英孙礼宾李英杰孙彦姚硕

分类号：TG316

出版年,卷(期):页码：2022,47(2):19-24

摘要：

在热锻过程中，模具表面不断受到循环机械载荷和热冲击的影响，因此，磨损成为模具失效的主要原因。针对汽车突缘叉模具磨损严重的问题，提出了一种突缘叉热锻成形工艺，基于Archard磨损理论模型，建立了突缘叉热锻成形过程中的热-力耦合有限元模型，并研究了热锻成形过程中锻件的成形情况，同时对模具磨损最严重的位置进行了预测，最后通过实验对有限元模拟结果进行了验证。模拟和实验结果表明：在整个热锻成形过程中，预锻后模具的磨损情况最为严重，其中预锻下模磨损最严重区域出现在型腔的圆角处；预锻下模在1000次锻造模拟后的最大总磨损深度为2.75 mm，而实际生产1000件后的最大总磨损深度为2.70 mm,模拟和实验测量结果基本相符，说明基于Archard磨损理论模型建立的突缘叉有限元模型能够比较准确地预测热锻后的模具磨损情况。

In hot forging process, the die surface is constantly affected by cyclic mechanical load and thermal shock, so wear has become the main cause of die failure.Aiming at the problem of serious die wear for automobile flange fork, a hot forging process of flange fork was put forward, and based on the Archard wear theory model, the thermal-mechanical coupling finite element model in the hot forging process of flange fork was established. Then, the forming situation of forgings in the hot forging process was studied, and the position of the most serious die wear was predicted. Finally, the finite element simulation results were verified by experiments. The simulation and experiment results show that the die wear situation after pre-forging is the most serious in the whole hot forging process, in which the most serious wear area of pre-forging lower die appears at the fillet of cavity, and the maximum total wear depth of the pre-forging lower die after 1000 times of forging simulations is 2.75 mm, while the maximum total wear depth after the actual production of 1000 forgings is 2.70 mm. The simulation results are basically consistent with the experimental results, which shows that the finite element model of flange fork established based on Archard wear theory model can accurately predict the die wear after hot forging.

基金项目：

上海市闵行区产学研合作计划（2019MHC073）

作者简介：李禧（1995-），男，硕士，E-mail：lixiyour@163.com；通信作者：张莹（1980-），女，博士，讲师，E-mail：jerrinzhang@163.com

参考文献：

[1]Gronostajski Z, Kaszuba M, Hawryluk M, et al. A review of the degradation mechanisms of the hot forging tools[J]. Archives of Civil and Mechanical Engineering, 2014, 14(4):528-539.

[2]Hawryluk M, Kaszuba M, Gronostajski Z, et al. Identification of the relations between the process conditions and the forging tool wear by combined experimental and numerical investigations[J]. CIRP Journal of Manufacturing Science and Technology, 2020, 30（4）:87-93.

[3]Lange K, Cser L, Geiger M, et al. Tool life and tool quality in bulk metal forming[J]. CIRP Annals, 1992, 41(2):667-675.

[4]Kang J H, Park I W, Jae J S, et al. A study on a die wear model considering thermal softening (I): Construction of the wear model[J]. Journal of Materials Processing Technology, 1999, 96(1-3):53-58.

[5]Kang J H, Park I W, Jae J S, et al. A study on die wear model considering thermal softening (II): Application of the suggested wear model[J]. Journal of Materials Processing Technology, 1999, 94(2):183-188.

[6]林高用, 冯迪, 郑小燕, 等. 基于Archard理论的挤压次数对模具磨损量的影响分析[J]. 中南大学学报：自然科学版, 2009, 40(5)：1245-1251.

Lin G Y, Feng D, Zheng X Y, et al. Analysis of influence of extrusion times on total die wear based on Archard theory[J]. Journal of Central South University：Science and Technology, 2009, 40(5):1245-1251.

[7]谢晖, 李江曼, 王诗恩, 等. 超高强钢板冲压模具磨损CAE分析研究与应用[J]. 湖南大学学报：自然科学版，2015，42(8)：15-21.

Xie H, Li J M, Wang S E, et al. Research and application of die wear CAE analysis of ultra high strength steel stamping[J]. Journal of Hunan University：Natural Sciences, 2015, 42(8):15-21.

[8]Luo S Y, Zhu D H, Hua L, et al. Numerical analysis of die wear characteristics in hot forging of titanium alloy turbine blade[J]. International Journal of Mechanical Sciences, 2017, 123:260-270.

[9]陆元三，李颖颖，王培安. 基于Archard理论对变速叉预锻凹模寿命分析[J].锻压技术，2020，45(8)：164-169.

Lu Y S, Li Y Y, Wang P A. Life analysis on pre-forging die for shifting fork based on Archard theory[J], Forging & Stamping Technology,2020, 45(8):164-169.

[10]Archard J F. Contact and rubbing of flat surfaces[J]. Journal of Applied Physics, 1953, 24(8):981-988.

[11]Lee G A, Im Y T. Finite-element investigation of the wear and elastic deformation of dies in metal forming[J]. Journal of Materials Processing Technology, 1999, 89-90:123-127.

[12]Huang W, Nie X, Zan X. Dynamic tensile behavior of 5CrMnMo at elevated temperatures[J]. Acta Metallurgica Sinica：English Letters, 2004, 17（4）:521-527.

服务与反馈：

【本网站尚未开通全文下载服务】【加入收藏】