锻压技术

汽车制动器推力杠杆模锻缺陷及工艺分析

英文标题：Die forging defects and process analysis for automobile brake thrust lever

作者：刘晓立1 2 3 刘虹1 郑富元1 刘志强1 赵昌德1 张明2 黄素霞3 王占一2 闫宾4 郭进喜2

单位：1.金马工业集团股份有限公司 2.河北工程大学机械与装备工程学院河北省智能工业装备技术重点实验室3.北京科技大学机械工程学院4.安阳工学院机械工程学院

分类号：TG316

出版年,卷(期):页码：2023,48(8):25-31

摘要：

流线缺陷是制约模锻产品质量的关键问题之一，因此,解决汽车零部件模锻过程中的流线缺陷问题已刻不容缓。基于塑性加工理论和热力耦合工艺，利用有限元DEFORM-3D软件建立了全流程模锻成形过程，对汽车制动器推力杠杆模锻成形过程中的流线缺陷问题进行了分析，并通过实验验证了模型的准确性。根据汽车制动器推力杠杆结构特征设计了两种模锻成形工艺方案JT和HJT，对比分析了两种方案的锻件成形过程、加载方式、锻件成形质量、锻件温度分布、锻件流线分布情况和受力分布等。研究表明：HJT方案可以改善模锻过程中的流线分布和受力分布，提高了锻件的抗拉强度和材料利用率,为解决流线缺陷问题奠定了理论基础。

Streamline defect is one of the key problems restricting the quality of die forging products, so it is urgent to solve the problem of streamline defect in the die forging process for automobile parts. Therefore, based on the plastic processing theory and thermal-mechanical coupling process, the whole process of die forging was established by finite element software DEFORM-3D, the streamline defect problems in the die forging process of automobile brake thrust lever were analyzed, and the accuracy of the model was verified by experiments. Then, according to the structural characteristics of automobile brake thrust lever, two die forging process schemes of JT and HJT were designed, and the forgings forming process, loading mode,forming quality of forgings, temperature distribution of forgings, streamline distribution of forgings and force distribution of the two schemes were compared and analyzed. The research shows that HJT scheme can improve the streamline distribution and loading distribution in the die forging process, and significantly improves the tensile strength and material utilization of the forgings, which lays a theoretical foundation for solving the problem of streamline defect.

基金项目：

河北省教育厅青年基金资助项目(QN2021209)；国家自然科学基金资助项目(52005148)；山东省科技型中小企业创新能力提升工程项目（2022TSGC2510，2022TSGC1231）；安阳市科技计划资助项目(2022C01GX015)

作者简介：刘晓立(1986-)，男，博士，讲师,E-mail：liuxiaoli01206332@163.com

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