新型阻力墙结构参数对曲轴终锻模磨损的影响

Effect of the Parameters of New Resistance Wall on Wear Resistance of Crankshaft Finish Forging Die

分析曲轴终锻模阻力墙结构中三个重要参数(高度h、间隙n、斜度α)对终锻模型腔凸缘部位最大磨损量(f)的影响,运用有限元分析软件Deform3D对曲轴终锻过程进行数值模拟仿真,并采用最小二乘法拟合得到了它们之间的影响规律曲线。研究结果表明:f随h的增加而增加,从磨损区域上来看,除凸缘部位外,型腔两端大、小头模口部位的磨损受h影响比较大,从保证终锻模具寿命的角度来看,h的设计值不能超过30mm;f随n的增加而降低,从磨损区域上来看,除凸缘部位外,凸台部位的磨损受n影响比较明显。当n取值大于3mm时,能有效地延缓凸台部位的磨损,从保证终锻模具寿命的角度来看,n的设计值不能小于2mm;f随α的增加而降低,从磨损区域分析来看,除凸缘部位外,阻力墙根部圆角过渡处的磨损受α影响比较大,为了将终锻模的磨损控制在理想的范围内,α的设计值不能小于10°。

The three imporant factors of resistance wall, including height （h）, clearance （n）, gradient（a） influencing on maximum wear loss on flange of finish forging （f） were studied. Furthermore, FEM software Deform3D was applied to simulate the crankshaft finish forming process, and the result was displayed in the form of graph through least square method. The results indicate the ＂f＂ raises while ＂h＂ increases. For the consideration of wear distribution, the wear of die orifice comer of both ends are affected more from ＂h＂ besides flange.In order to control the wear of finish forging die, ＂h＂ cannot be designed above 30 mm. ＂f＂ increases while the ＂n＂ decreases. For the consideration of wear distribution, the wear of boss is affected more from ＂n＂ besides flange. On the premise of assuring forging＇s forming quality, the wear of boss would be delayed if ＂n＂ above 3mm. In order to control the wear of finish forging die, ＂n＂ cannot be designed below 2 mm. ＂f ＂ decreases as the ＂a＂ increases. For the consideration of wear distribution, the wear of fillet radius of resistance wall root is affected more from ＂a＂ besides flange. In order to control the wear of finish forging die, ＂a＂ cannot be designed below 10°.