一种基于三维静电场模拟的预制坯设计新方法

A New Method of Preform Design Based on 3-D Electrostatic Fields

预制坯设计是锻造工艺设计中的重要内容之一。笔者以某TC4合金叶片为例提出了一种基于三维静电场模拟的预制坯设计新方法,该方法利用塑性变形过程中坯料流动规律类似于静电场等势线这一特征,通过三维静电场模拟选取合适的等势线作为预制坯的基本外形轮廓,并通过等势线的分布来判断坯料成形时的流动特征,从而可以判断锻造成形过程中可能出现的缺陷。结果表明:基于三维静电场设计的预制坯成形后锻件轮廓清晰,坯料流动更趋合理,变形更均匀,并能有效降低成形载荷。提出的设计方法特别适合于复杂形状锻件及难变形材料的预制坯设计。

Preform design is important for forging process design. Based on the 3-D electrostatic fields, a new method of preform design was brought forward by the example of TC4 alloy blade. The contour figure of the preform was obtained through selecting suitable equipotential lines by simulation of 3-D electrostatic field, which utilized the similarity between the blank flow law and the isopotential line of the electrostatic field. The flowing characteristics of billet in the forming process can be analyzed by the distribution of isopotential lines so that the possible defect in the forging process can be predicted. The simulation results show that the final forging using the preform based on 3-D electrostatic fields has clear contour, the blank flow is more reasonable, deformation is more uniform, and the lower forging load is obtained. The design method in this paper is especially suitable for preform design of forgings with complex surface morphology and difficult-of- deformation materials.