法兰盘模锻成形力控制的研究

Research on die forming force of splined shaft flange

根据花键轴法兰盘锻件的外形结构特点,采用理论分析和有限元模拟相结合的方法,制定了3步模锻成形工艺。法兰盘厚度薄,3个凸耳部位需要较多的金属,成形力的控制是该工艺的难点。采用以下3个措施有效降低了终锻成形力:采用温成形;在预锻工步利用楔形模面合理分配金属,在终锻成形时改善金属的流动性;在法兰中部凸台部位设置余料腔,储存多余的金属。通过数值模拟,证明了模锻工艺的可行性。最后,通过工艺实验,得到了合格锻件。设计的带有楔形法兰的预锻件,不仅解决了预锻聚料问题,而且也有利于终锻成形。

Based on the structure characteristics of the splined shaft flange, the die forging process with three steps was laid down by theo- retical analysis and FEA. The splined shaft flange had thin thickness with three ears that needed more metal to form, so the key problem of the process was the control of die forming force. The three following measurements could reduce the final forging force effectively ： using warm forming, distributing metal reasonably by wedge-shaped die surfaces in pre-forging step to improve metal flowing in final forming, and setting residual material cavity on the boss in flange center in order to contain the residual metal. The feasibility of die forging process was proved by FEA. At last, the qualified forging was obtained by experiment. Pre-forging part designed with wedge-shaped flange can solve the problem of accumulating material in pre-forging step, and it is benefit for finished forging.