基于有限体积模拟的模锻优化设计

Optimum design based FVM for the open-die forging

在锻造等金属大变形的工艺设计中,相关参数的确定很大程度上依赖于经验公式,而有限元法在金属大变形过程数值模拟中有明显的局限性,且模拟结果难以验证。本文基于有限体积法模拟了一典型开式模锻过程,并在通用经验值允许的范围内,根据模拟结果调整工艺设计中的参数设置,有效避免了一种锻件常见缺陷。通过分析变形过程特定时段的变形区形状、分流面的变化及变形力分布曲线,结合相关塑性理论验证了模拟结果的正确性,实现了工艺优化设计。研究证明理论预测与数值模拟相"拟合"的方法可以代替实验用于指导生产实践。

Many processing parameters are calculated with empirical equation in technological design about metal large deformation. Otherwise, there is limitation for the numerical simulation of metal large deformation processing with FEM. It is also difficult for the certification of simulation result. In this paper, a typical open-die forging processing was simulated based on FVM. According to the simulation result, some processing parameters were adjusted in a proper extent. And a common defect of forge piece can be avoided in this way. By analyzing the deformed area, material flow and force-travel curve, the simulation result was certified with related plastic theory. Optimum design can be realized in the same time. It is approved that the method bonding theoretical prediction and numerical simulation together can be used for productive practice in place of experiment.