Transactions of Materials and Heat Treatment

Title：Wear analysis and prediction on final forging die of automobile flange based on response surface method

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ClassificationCode：TG316

year,vol(issue):pagenumber：2022,47(7):200-205

Abstract：

A company used two pre-forging and one final forging to form automobile flange forgings, but it was found that the service life of final forging die was obviously lower than that of pre-forging die during production. Therefore, in order to improve the service life of the final forging die, the final forging process of flange was simulated by software Deform-3D, and the die wear condition was studied by introducing Archard wear model. Then, taking impact speed, die hardness, billet temperature and mold preheating temperature as the optimization parameters and taking the minimum die wear depth as the optimization objective, through the response surface method, the second-order response surface model about experimental optimization parameters and die wear depth and the best parameter combination scheme were obtained, and the best parameter combination was the impact speed of 38.5 mm·s-1, the die hardness of 60 HRC, the billet temperature of 400 ℃ and the mold preheating temperature of 360 ℃, which were verified by Deform-3D. The results show that the die wear depth is significantly reduced compared with that before optimization. Based on the optimization results, the trial production of flange was carried out. The sizes and performance of forgings meet the design requirements, and the service life of die is increased from 3200 to 5430 pieces, which is close to the simulation prediction results, indicating that the combined application of CAE analysis and RSM can effectively solve the problem of die wear.

Funds：

国家重点研发计划资助项目（2017YFC0804804）

作者简介：蔡加加（1989-），男，硕士，工程师 E-mail：caijiajia0818@126.com 通信作者：王东方（1961-），男，硕士，教授 E-mail：xiyue412@aliyun.com

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