锻压技术

重型卡车前轴成形全过程的有限元仿真及工艺优化

英文标题：Finite element simulation of whole process and process optimization on front axle forming for heavy truck

作者：左磊张伟

分类号：TG316

出版年,卷(期):页码：2022,47(11):55-61

摘要：

为解决某重型卡车前轴锻件的折叠和填充不满等缺陷问题，对某重型卡车前轴成形全过程进行有限元数值仿真及工艺优化研究。基于经验数据和锻模设计理论，设计了各道次的模具并构建了相应的有限元模型。结果表明：预锻工序中，坯料两端区域首先与模具接触从而使材料向中心区域流动，中心区域工字梁区域的坯料被挤长发生失稳，进而材料向上或者向下流动而发生弯曲，使得材料发生偏移，流动至飞边区域，导致中间工字梁区域缺失材料，进而造成工字梁区域发生填充不满缺陷。通过减小坯料工字梁区域的长度，使得中间工字梁区域在与模具接触前不发生明显的弯曲变形，可避免填充不满缺陷。由于坯料与辊锻模之间存在相对滑移，使得坯料辊锻后不关于中心区域对称，在第2道次辊锻时出现薄边现象，进而使得后续模锻工序中出现折叠缺陷。通过控制坯料端面与辊中心的距离来抵消辊锻过程中辊与坯料之间滑移导致的辊锻位置误差，可以避免薄边现象出现，进而避免折叠缺陷。使用优化后的工艺参数进行实际生产，前轴锻件的表面质量良好，无折叠和填充不满等缺陷。

In order to solve the defects such as folding and insufficient filling of front axle forgings for heavy truck, the whole forming process of front axle for heavy truck was studied by finite element numerical simulation and process optimization. Then, based on the empirical data and forging die design theory, the mold of each pass was designed, and the corresponding finite element model was constructed. The results show that in the pre-forging step, the regions at both ends of billet first contact with the mold so that the material flows to the central region, and the billet of I-beam in the central region is extruded and unstable. Furthermore, the material flows upward or downward and bends, causing the material offsets and flows to the flash region, resulting in the lack of material in the middle I-beam region, which in turn causes the insufficient filling defect of I-beam region. However, by reducing the length of the billet I-beam region, there is no obvious bending deformation in the middle I-beam region before contacting with the mold, and the insufficient filling defect is avoided. Due to the relative slip between billet and roll forging mold, the billet is not symmetrical at the central region after roll forging, and the thin edge phenomenon occurs during the second pass of roll forging, resulting in folding defects in the subsequent die forging step. By controlling the distance between the end face of billet and the roll center to offset the roll forging position error caused by the slip between roll and billet in the roll forging process, the thin edge phenomenon and the folding defect are avoided. Thus, using the optimized process parameters for actual production, the surface quality of the front axle forgings is good, and there is no defects such as folding and insufficient filling.

基金项目：

2019重庆市教委科学技术研究项目(KJQN201904001)

作者简介：左磊(1972-)，男，本科，高级讲师，E-mail：406666051@qq.com

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