基于Deform-3D的花键轴叉热锻成形工艺优化

Process optimization on hot forging for spline shaft fork based on Deform-3D

针对花键轴叉锻件传统锻造工艺耗料多的问题,提出立式预锻、杆部热挤成形的预锻成形方法,给出了立式预锻的模具结构设计,并对热挤预锻模具进行了参数优化,解决了充填不足的问题,最终锻出低能耗、低料耗、高生产率的合格锻件。基于Deform-3D有限元分析软件模拟观察到花键轴叉锻件的成形过程,准确分析出缺陷形成的原因和工艺优化后锻件成形效果。通过实际生产验证了模拟结果的可靠性,在优化预锻件脱模斜度和终锻模具桥部参数后,生产效率提高至少20%,料耗节省约15%,终锻模具磨损量降低约25%,模具寿命得到明显提升。

For the problem of excessive material consumption in the traditional forging process for spline shaft fork,the vertical pre-forging and stem hot extrusion were put forward,and the die structure design in the vertical pre-forging was given. Then,the hot extrusion mold parameters were optimized to solve the insufficient filling problem. Finally,the qualified forging workpieces were produced with less energy consumption,less material consumption and higher productivity. Furthermore,the forging process of spline shaft fork was observed by the finite element analysis software Deform-3D,and the causes of defect and the forming effects after parameter optimization were accurately analyzed. It is proved that the simulation results are reliable through actual production. Actual production shows that the productivity is increased by 20% at least,the material consumption is saved about 15%,the final forging die wear is decreased by about 25%,and the die life is increased obviously by the optimum parameters of pre-forging ejection gradient and final forging die bridge.