敷料设计对曲轴模锻金属充填的影响

Influence of dressing design on metal filling in crankshaft drop forging

以三缸曲轴的模锻工艺为例,研究敷料设计对曲轴模锻成形中的金属流动规律的影响。建立了不同的敷料和连皮设计方案,通过数值模拟获得了曲轴平衡块的成形效果,并分析了敷料处的金属流动速度、成形载荷和模具应力。研究结果表明,设置敷料可以有效改善曲轴平衡块的充填效果,同时不会引起成形载荷和模具应力的大幅上升;敷料位置应靠近连杆颈而远离飞边桥以减少金属外流,敷料体积应根据平衡块的充填效果而定。

Take the drop forging process of a three-cylinder crankshaft for example, the influence of dressing design on the metal flow in crankshaft drop forging was studied. Different designs of dressing and counterweights were proposed and used for numerical simulation, the filling effects of crankshaft counterweights were obtained, and the metal flow velocity, forming load and die stress at dressing were ana- lyzed. The finite element analysis shows that the filling effect of crankshaft counterweights can be effectively improved by setting dressings without the substantial increasing of the forming load and die stress. Dressings should be positioned close to the connecting rod journal while far away from the flash bridge to reduce the outflow of metal. However, its volume should be balanced according to the filling effect of counterweights.