Transactions of Materials and Heat Treatment

Title：Forging process simulation and die structure improvement on flange drive shaft based on finite element

Authors： Zeng Yicong Xu Hailiang

Unit： School of Electronic Information Engineering Changsha Social Work College School of Mechanical and Electrical Engineering Central South University

KeyWords： flange drive shaft modeling and simulations metal streamline Archard modified model mold wear

ClassificationCode：TG315.2

year,vol(issue):pagenumber：2022,47(11):187-195

Abstract：

A flange drive shaft was formed by five processes, including upsetting, primary extrusion, secondary extrusion, pre-forging and final forging，and after long-term production, it was found that the mold wear and failure of process 3 was fast and the mold change frequency was high, which seriously affected the production efficiency of product. Then, in order to solve this problem, the mold structure of process 3 was improved. Furthermore, two improvement schemes were designed according to its structural characteristics, and the modeling and simulation were carried out respectively based on Deform-3D. Firstly, the original process was numerically analyzed to preliminarily verify the reliability of Archard modified model. Secondly, the forming integrity and the change of metal streamline for forgings in the improved scheme were analyzed to judge whether there were forming defects in forgings, and the change conditions of mold wear before and after improvement were compared. Finally, the simulation analysis results were verified by test. The results show that the test results are in good agreement with the simulation results, the modeling analysis is accurate, the improved scheme can realize the forming of forgings, and the forming effect of scheme 1 is better. Thus, in the premise of not affecting the mold life of process 4, the average mold life of process 3 is increased from 3472 pieces to 6235 pieces, which solves the problem of enterprise very well.

Funds：

国家自然科学基金面上项目（51375499）

作者简介：曾义聪（1973-），男，硕士，副教授，E-mail：zycong0075@163.com；通信作者：徐海良（1965-），男，博士，教授，E-mail：csuxhliang@aliyun.com

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