锻压技术

基于响应面法的汽车法兰盘终锻模具磨损分析与预测

英文标题：Wear analysis and prediction on final forging die of automobile flange based on response surface method

作者：蔡加加王东方王亚

分类号：TG316

出版年,卷(期):页码：2022,47(7):200-205

摘要：

某公司采用两次预锻、一次终锻成形汽车法兰盘锻件，但在生产中发现终锻凹模的寿命明显低于预锻凹模，因此为提高终锻凹模寿命，采用Deform-3D软件对法兰盘终锻过程进行了数值模拟，并引入Archard磨损模型，对凹模磨损情况进行了研究。并选取打击速度、凹模硬度、坯料温度以及模具预热温度作为优化参数，以凹模磨损深度最小作为优化目标，通过响应面法，获得了关于实验优化参数与凹模磨损深度的二阶响应面模型及最佳参数组合方案，即打击速度为38.5 mm·s-1、凹模硬度为60 HRC、坯料温度为400 ℃、模具预热温度为360 ℃。通过Deform-3D对优化后的参数进行了验证，结果表明凹模磨损深度与优化前相比得到了明显降低。基于优化结果，对法兰盘进行了试生产，获得的锻件的尺寸和性能均能满足设计要求，凹模寿命从3200件提高至5430件，与模拟预测结果相近，表明CAE分析与RSM的结合应用能够有效地解决模具磨损问题。

A company used two pre-forging and one final forging to form automobile flange forgings, but it was found that the service life of final forging die was obviously lower than that of pre-forging die during production. Therefore, in order to improve the service life of the final forging die, the final forging process of flange was simulated by software Deform-3D, and the die wear condition was studied by introducing Archard wear model. Then, taking impact speed, die hardness, billet temperature and mold preheating temperature as the optimization parameters and taking the minimum die wear depth as the optimization objective, through the response surface method, the second-order response surface model about experimental optimization parameters and die wear depth and the best parameter combination scheme were obtained, and the best parameter combination was the impact speed of 38.5 mm·s-1, the die hardness of 60 HRC, the billet temperature of 400 ℃ and the mold preheating temperature of 360 ℃, which were verified by Deform-3D. The results show that the die wear depth is significantly reduced compared with that before optimization. Based on the optimization results, the trial production of flange was carried out. The sizes and performance of forgings meet the design requirements, and the service life of die is increased from 3200 to 5430 pieces, which is close to the simulation prediction results, indicating that the combined application of CAE analysis and RSM can effectively solve the problem of die wear.

基金项目：

国家重点研发计划资助项目（2017YFC0804804）

作者简介：蔡加加（1989-），男，硕士，工程师 E-mail：caijiajia0818@126.com 通信作者：王东方（1961-），男，硕士，教授 E-mail：xiyue412@aliyun.com

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