曲轴无飞边精密成形模具系统开发

Development of Flashless Precision Forming Tool System for Crankshaft

为了解决曲轴模锻材料利用率低和能耗高的问题,基于有限元数值模拟技术,研究了热锻曲轴的无飞边精密成形工艺及模具系统。由于曲轴的几何结构单元主要为单缸曲轴,故首先给出了单缸曲轴的热锻工序,包括板式楔横轧、多向锻造和精锻。利用DEFORM 3D软件对曲轴的无飞边锻造过程进行全程数值模拟,结果表明:楔横轧工序中工件两端易突起,多向锻造中连杆颈圆角容易折叠,精锻中主轴颈圆角处容易折叠;楔横轧工序最大载荷为250 k N,多向锻造X向最大载荷为450 k N,精锻最大载荷为5 450 k N。最后将该技术推广到两缸曲轴和多缸曲轴,同样得到了良好的无飞边结果。

Flashless precision forming process and mould systems of a hot forging crankshaft was studied based on finite element numerical simulation technique in order to solve the problem of low material utilization rate and high energy consumption in the drop forging of crankshaft. As the main geometric unit of crankshaft is single-cylinder crankshaft,the forging process of a single-cylinder crankshaft was given firstly,including plate-type cross wedge rolling,multidirectional forging and precision forging. Forging process of crankshaft without flash was simulated via DEFORM 3D software,the results show that： apophysis occurs easily at ends of work piece in cross wedge rolling process,and fold defect appears at the fillet of journal in multi-directional forging and at the fillet of bearing in precious forging; cross wedge rolling process executes with maximum load of 250 KN,multi-directional forging with X directional maximum load of 450 KN,and precious forging with maximum load of 5 450 KN. Finally,promoting technology to two-cylinder and multi-cylinder crankshaft also obtains a good result without flash.