锻压技术

基于CAE的汽车铝合金控制臂锻造成形工艺

英文标题：Forging process on automotive aluminum alloy control arm based on CAE

分类号：TG316

出版年,卷(期):页码：2024,49(3):1-7

摘要：

以某汽车右上控制臂为研究对象，选用6082铝合金为锻造材料，分析了产品的结构特点及成形难点，确定了其成形工艺为两道次辊锻、两工位弯曲、预锻和终锻。根据锻模设计理论，采用Solidworks软件设计各道次模具，并通过Deform软件对6082铝合金控制臂成形过程进行模拟，从温度分布、等效应力应变以及金属流动等角度分析了各工序的成形情况。针对成形方案中变形程度最大的预锻工序，采用控制单一变量的方法，分析了坯料始锻温度及摩擦因数对预锻成形的影响。结果表明：预锻时，随着始锻温度的增加，平均等效应力减小，始锻温度在450~490 ℃时更合理；改善润滑，减小摩擦因数使得模具载荷降低，锻件的最大等效应变减小，有利于成形且提升模具寿命。最后，基于模拟结果结合实际生产进行了试验，得到了与模拟结果相吻合的成形锻件。

For the upper right control arm of an automobile, taking 6082 aluminum alloy as the forging material, the structural characteristics and forming difficulties of product were analyzed, and its forming process was determined to be two-pass roll forging, two-station bending, pre-forging and final forging. Then, according to the design theory of forging die, each pass die was designed by software Solidworks, the forming process of 6082 aluminum alloy control arm was simulated by software Deform, and the forming situation of each process was analyzed from the perspective of temperature distribution, stress-strain and metal flow. Furthermore, for the pre-forging process with the largest deformation degree in the forming scheme, the influences of billet temperature and friction factor on the pre-forging forming were analyzed by controlling a single variable. The results show that during pre-forging, with the increasing of initial forging temperature, the average equivalent stress decreases, and the initial forging temperature is more reasonable at 450-490 ℃. Moreover, improved lubrication and reduced friction factors can reduce the die load and the maximum equivalent strain of forgings, and prolong the service life of die. Finally, based on the simulation results and combined with the actual production, the experiment shows that the formed forgings obtained is consistent with the simulation results.

基金项目：

国家自然科学基金资助项目（51775249）

作者简介：周礼菊（1999-），女，硕士研究生，E-mail：ljzhou9907@163.com；通信作者：王雷刚（1963-），男，博士，教授，博士生导师，E-mail：lgwang@mail.ujs.edu.cn

参考文献：

[1]邹喜红,苟林林,傅雷，等.基于实测载荷谱的某全域车悬架下控制臂疲劳寿命研究[J].兵器装备工程学报,2022,43(7):301-308.

Zou X H, Gou L L, Fu L, et al. Research on fatigue life of all-terrain vehicle control arm based on measured load spectrum[J]. Journal of Ordnance Equipment Engineering,2022,43(7):301-308.

[2]孙伟,王玲.铝合金锻造技术在汽车工业中的应用[J].锻造与冲压,2021，(15):20-24.

Sun W, Wang L. Application of aluminum alloy forging technology in automobile industry[J].Forging & Metalforming,2021，(15):20-24.

[3]赵东林.镁合金汽车控制臂铸锻复合成形工艺的研究开发[D].重庆：重庆大学,2012.

Zhao D L.The Research and Development of Casting-Forging Combined Process Forming Process of Magnesium Alloy Control Arm of Automobile[D].Chongqing:Chongqing University,2012.

[4]胡文硕,郑顺奇,陈刚,等.汽车控制臂锻坯结构与浇注系统优化[J].兵器材料科学与工程,2022,45(3):81-86.

Hu W S, Zheng S Q,Chen G, et al. Optimization of forging billet structure and gating system of automobile control arm[J].Ordnance Material Science and Engineering,2022,45(3):81-86.

[5]Qian X M, Parson N, Chen X G. Effects of Mn addition and related Mn-containing dispersoids on the hot deformation behavior of 6082 aluminum alloys[J]. Materials Science and Engineering:A,2019, 764(3):138253.

[6]Deng L, Zhang H D, Li G A，et al. Processing map and hot deformation behavior of squeeze cast 6082 aluminum alloy[J]. Transactions of Nonferrous Metals Society of China,2022,32(7):2150-2163.

[7]张辉,石文超,杨大强,等.铝合金控制臂辊锻制坯模锻工艺数值模拟[J].精密成形工程,2012,4(2):60-63，66.

Zhang H, Shi W C, Yang D Q, et al. Numerical simulation on the roll-forging and die-forging of aluminum alloy control arms[J]. Journal of Netshape Forming Engineering,2012,4(2):60-63，66.

[8]金云光,王雷刚,黄瑶,等.Solidworks在辊锻制坯中的应用[J].锻压装备与制造技术,2003,(4):36-38.

Jin Y G,Wang L G,Huang Y, et al. Applications of Solidworks in roll forging blanking[J].China Metalforming Equipment & Manufacturing Technology,2003,(4):36-38.

[9]陈钰金,邵长斌,李思奇，等.锻造铝合金控制臂弯曲工艺分析与优化[J].锻压技术,2023,48(6):17-21.

Chen Y J, Shao C B, Li S Q, et al. Analysis and optimization on bending process for forging aluminum alloy control arm[J]. Forging & Stamping Technology,2023,48(6):17-21.

[10]孙伟领. 铝合金控制臂锻造工艺优化与数值分析[D].北京：中国机械科学研究总院集团有限公司,2020.

Sun W L. Optimization and Numerical Analysis of Forging Process of Aluminum Alloy Control Arm[D].Beijing: China Academy of Machinery Science and Technology Group,2020.

[11]韦韡,蒋鹏,曹飞.6082铝合金的高温本构关系[J].塑性工程学报,2013,20(2):100-106.

Wei W, Jiang P, Cao F.Constitutive equations for hot deformation of 6082 aluminum alloy[J].Journal of Plasticity Engineering,2013,20(2):100-106.

[12]邹永恒,陶虹,徐国明,等.6082铝合金热处理工艺参数的研究[J].金属热处理,2007, 32(10):71-76.

Zou Y H, Tao H, Xu G M, et al. Research on heat treatment parameters of 6082 aluminum alloy [J]. Heat Treatment of Metals,2007, 32(10):71-76.

[13]章立预.冷温热精锻模具润滑与寿命[J].锻造与冲压,2020，(9):32，34-36.

Zhang L Y. Lubrication and die life in cold，warm and precision hot forging[J].Forging & Metalforming,2020，(9):32，34-36.

服务与反馈：

【文章下载】【加入收藏】