多斜孔钢框架关键结构锻件成形模拟及工艺优化

Numerical simulation of forming and process optimization for forgings with inclined multi-hole key structure steel frame

针对建筑上多斜孔钢框架关键结构锻件在锻造成形中易产生四角斜孔边缘折叠、四角充填不完全、成形载荷大和模具寿命低的问题,依据不同形状下的初始毛坯在终锻成形时的不同成形效果,提出了基于毛坯形状优化的精整方法。借助数值模拟软件Deform-3D模拟和分析了钢框架关键结构件锻造成形过程,结果表明采用新工艺锻件成形良好、模具受载合理。并采用黄金分割法,以成形载荷为目标函数,对初始毛坯形状的精整参数进行优化设计,在保证锻件成形饱满的情况下,使成形载荷降低了12.32%。最后,通过生产实践验证了模拟结果与生产实际基本一致,锻件质量满足要求,无折叠、充填不完全等缺陷;模具的锻打数量增加,提高了模具的使用寿命。

For folding defects in the edge of inclined hole grooves,unfilled zones in the four corners,large forming load and short die life during the forming process of inclined multi-hole key structure forgings for steel frame,a finishing method of optimizing blank shape was put forward based on the different forming effects in the final forging with different initial blank shapes. The forging process of key steel frame structure was simulated and analyzed by simulation software Deform- 3D. Results show that a good forming quality of forgings and a reasonable mold load are gotten by the new technology. And with the golden section method,the forming load is taken as objective function,finishing parameters of the initial blank shape are optimized,which make the forming load reduce by 12. 32% when the forging is full filled,so the die life is improved. Finally,results are basically consistent between the production experiment and simulation through the production practice. The quality of forging parts meets the product requirements without defects such as folding and incomplete filling.The number of die forging parts is increased and the working life of die is improved.