异形齿盘毂热锻成形工艺数值模拟与优化设计

Optimization design and numerical simulation of hot forging process for special tooth disc-hub

针对带有异形齿法兰的盘毂零件提出了热冷复合成形工艺。结合正交试验设计方法和有限元模拟技术对新工艺中热锻成形过程进行分析和工艺参数优化设计,以降低盘毂热锻成形峰值载荷、降低终锻件最大损伤值、减少模具磨损为评价指标,研究了坯料始锻温度、热锻件连皮厚度、下盲孔高度、挤压速度和润滑系数对热锻成形效果的影响,并获得了优化的工艺参数组合,即坯料始锻温度为1100℃、连皮厚度16.0 mm、下盲孔高度10.0 mm、挤压速度250 mm·s-1、摩擦系数0.2。经生产试验验证,优化后的盘毂热锻成形工艺能够为后续的冷精整工艺提供质量合格的锻件。

The hot and cold composite forming technology was proposed to manufacture a kind of special tooth disc-hub. The hot forging process was analyzed and the process parameters were optimized by combining the orthogonal test with FEM. Regarding the reductions of the maximum forming load, the maximum damage and die wear as evaluation indexes, it was studied the influences of initial forming temperature, web thickness, the bottom blind hole height, extrusion velocity and lubricating factor on hot forging, and the suitable process parameters were obtained as follows： billet initial forming temperature 1100℃, web thickness 16.0 mm, the height of bottom blind hole 16.0 mm, extrusion velocity 250 mm· s-1 and lubricating factor 0. 2. The technological practice shows that the optimized method can manufacture qualified hot forging parts for subsequent cold sizing process.