基于有限元的发动机曲轴辊锻模具结构优化设计与试验验证

Structure Optimization Design of Engine Crankshaft Roll Forging Die Based on Finite Element and Its Experimental Validation

某型号曲轴在辊锻制坯阶段模具磨损严重,导致成形时出现折叠。为了解决此问题,选取过渡圆角、入模圆角、过渡斜度三个关键参数,以降低磨损量为目标,基于正交试验进行模具结构优化研究。结果显示,当过渡斜度为40°,过渡圆角为25 mm,入模圆角为20 mm时,磨损量最小。通过生产试制验证了此次优化改进的合理性和正确性。

As die wear of a type of crankshaft is serious in the roll forging billet, it causes folding in forming. In order to solve this problem,choosing three key parameters（the transition radius,the die entrance fillet and the transition slope）, and taking reducing the wear extent as the goal, die structure optimization was carried out based on the orthogonal experiment.The results show that when the transition slope is 40°, transition radius is 25 mm, and the die entrance fillet is 20 mm, the wear extent is the minimum. The correctness and rationality of optimization and improvement were validated by production trial.