锻压技术

基于FEA的齿坯锻造模具寿命的提高

英文标题：Improvement of service life for gear blank forging die based on FEA

作者：张浩郭磊

分类号：TG315.2

出版年,卷(期):页码：2022,47(10):250-256

摘要：

为了节省耗材、减少工序、提高产品的精度和性能，齿坯的制造方式正逐渐由开式锻造转变为闭式锻造，但闭式锻造通常需要更大的成形力，易引起模具开裂、加剧模具磨损。针对该问题，对某齿坯的两种闭式锻造结构进行了分析，确定了合适的锻模结构，解决了模具开裂的问题，模具寿命从2600件提升至4120件。在此基础上，采用有限元分析（FEA）和正交试验相结合的方法，获得了不同组合的坯料加热温度、模具预热温度、上模底角、上模圆角等工艺参数对上模单次磨损深度的影响，并以降低上模单次磨损为最终目的，通过极差分析法确定了各参数的最优水平值。而后采用最优参数，以累计磨损方式连续进行24次锻造模拟，并拟合获得了上模总磨损深度与锻造次数的函数模型，依此推测出上模寿命。工艺参数改进后，模具寿命从4120件提升至7860件。

In order to save consumables, reduce processes and improve accuracy and performance of product, the manufacturing method of gear blank is gradually changing from open forging to closed forging, but the closed forging usually requires greater forming force, which is easy to cause die cracking and aggravate die wear. Therefore, aiming at this problem, two kinds of closed forging structures of gear was increased were analyzed, and the appropriate forging die structure was determined to solve the problem of die cracking and the die life from 2600 pieces to 4120 pieces. On this basis, using the method of combining finite element analysis (FEA) and orthogonal test, the influences of different combinations of blank heating temperature, die preheating temperature, upper die bottom angle and upper die fillet on the single wear depth of the upper die were obtained, and with the ultimate goal of reducing the single wear of the upper die, the optimal level of each parameter was determined by the range analysis method. Then, the optimal parameters were used to simulate twenty-four times of forging in the form of cumulative wear, the functional model of the total wear depth of the upper die and the number of forging was obtained by fitting, and the service life of the upper die was inferred. Thus, after the process parameters were improved, the service life of die was increased from 4120 pieces to 7860 pieces.

基金项目：

张浩（1985-），男，硕士，高级讲师，E-mail：zhanghao198508@163.com；通信作者：郭磊（1978-），男，博士，教授，E-mail：13824760975@139.com

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