锻压技术

基于克里金模型和数值仿真的汽车转向节成形工艺优化

英文标题：Optimization on forming process of automobile steering knuckle based on Kriging model and numerical simulation

作者：黄进

分类号：TG316

出版年,卷(期):页码：2024,49(11):8-15

摘要：

针对某汽车转向节热锻成形过程中存在的欠填充和成形载荷过大等问题，采用Forge有限元软件进行仿真优化。首先，基于热压缩实验，建立了40Cr钢的Hensel-Spittel本构模型；其次，选取阻力墙结构参数作为优化设计变量，开展了正交实验设计和数值仿真；最后，构建了响应面模型，并利用多目标遗传算法进行了优化。研究表明，40Cr钢在1123 K以上发生再结晶软化，且温度升高和应变速率降低时，软化现象愈加明显。当温度超过1123 K且应变速率低于1 s-1时，出现显著应力峰值；Hensel-Spittel模型能够高精度预测材料的高温流变特性，其参数易于求解；合理设计的阻力墙结构能够有效改变坯料流动规律，确保填充性能。实际生产试制结果验证了从最优前沿解集中选取的最优解可获得合格锻件。

For the problems of insufficient filling and excessive forming load in the hot forging process of a certain automotive steering knuckle, the simulation optimization was conducted by using finite element software Forge. First, a Hensel-Spittel constitutive model for 40Cr steel was established based on hot compression experiments. Next, the structure parameters of resistance wall were selected as the optimization design variables, and the orthogonal experimental design and numerical simulations were carried out. Finally, a response surface model was constructed, and the optimization was performed by using a multi-objective genetic algorithm. The research shows that 40Cr steel undergoes recrystallization softening above 1123 K, and the softening phenomenon becomes more pronounced as the temperature increases and the strain rate decreases. When the temperature exceeds 1123 K and the strain rate is below 1 s-1, a significant stress peak occurs. The Hensel-Spittel model can accurately predict the high-temperature rheological characteristics of the material, and the parameters are easy to solve. A well-designed resistance wall structure can effectively change the flow laws of blank and ensures the filling performance. The actual production trial results have verified that the optimal solution selected from the optimal frontier solution set can obtain qualified forgings.

基金项目：

重庆市职业教育教学改革研究项目(Z233028)；重庆工业职业技术学院教育科学规划项目(2023GZYJYGHY-02)

作者简介：黄进(1981-)，男，博士研究生，副教授 E-mail：huangjin@cqipc.edu.cn

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