汽车轮毂铸锻一体化制造工艺

Integrated casting and forging process for aluminum alloy automobile wheel

为生产高性能、低成本、重量轻的汽车轮毂,铝合金材料得到广泛应用;为降低部件的重量,结构轻量化技术被普遍应用于产品设计阶段。传统轮毂铸造工艺对零件性能有所提高,但对其内部组织的改善并不明显。铸锻一体化成形工艺则可以减少甚至消除铸造缺陷,提高工件性能,与铸造工艺相比,该工艺成形出的铝合金轮毂性能接近锻造的铝合金轮毂,质量高,重量轻,且比锻造工艺成本低、工艺简单。文章以17in.铝合金汽车轮毂为对象,采用拓扑优化方法对轮毂进行轻量化设计,并采用有限元仿真与实验相结合的方法,对铝合金轮毂的铸锻一体化成形工艺进行深入研究。通过FORGE软件对铝合金汽车轮毂铸锻一体化成形工艺的主要影响因素,即模具温度、活塞压射压力、锻造速度进行有限元仿真,得到不同参数对成形过程的影响规律。

To produce high-performance ,low-cost ,lightweight automobile wheel ,aluminum alloy material is widely used .In or-der to further reduce the weight of components ,topology optimization technology is applied to the product design stage .The tra-ditional wheel casting process can improve the performance of the components ,but the improvement of microstructure and me-chanical properties is not obvious .The components can be produced by integrated casting and forging process with less casting de-fects and high performance .Using this technology ,aluminum alloy automobile wheel can achieve high quality and light weight . The mechanical properties of aluminum alloy automobile wheel are close to that of the forging wheel .Compared with the forging process ,this technology is relatively cost-effective .In this paper ,integrated casting and forging process of 17 inches alloy auto-mobile wheels is studied by combining the finite element simulation with the experiment .The forming processes under different processing parameters were simulated by FORGE software to investigate the influence of mold temperature ,pressure of injection pistons and forging speed on the integrated casting and forging process .