基于类等势场和响应面法的复杂锻件预成形优化设计

Preform Optimization of Complex Part Based on Quasi-equipotential Field and Response Surface Methods

为实现复杂锻件的预成形设计,以连杆的热锻预成形设计为研究对象,建立基于类等势场和响应面分析的三维复杂锻件的预成形设计方法。在分析毛坯与终锻件间等势场分布规律与特点的基础上,采用逆向拟合法提取等势面及线面光顺处理,实现等势面的高效精确重构。针对长轴类锻件的预成形设计要求,提出沿零件的长、宽、高分别设置合理的缩放因子的非均匀缩放方法。实现了预成形件材料分布的合理调控,获得了优化的预锻件和辊锻毛坯,最终获得了充填完整、无任何成形缺陷且飞边小的连杆终锻件。数值模拟结果表明,所建立的方法能较好实现复杂锻件的预成形优化设计。

To realize preform design of complex forgings, the connecting rod was taken as the research objective. Based on quasi-equipotential field and response surface methods, the preform design method for three-dimensional complex forgings was established. Based on analysis on distribution regularities and characteristics of potential field between blank and finished forging, the reverse fitting method was proposed to extract the equipotential plane and line surface for smoothing treatment to reconstruct equi-potential surfaces efficiently and precisely. Targeted to preform design requirement on long-shaft forgings, the uniform scaling method which requires setting reasonable scaling factors along length, width and height of parts was proposed. It achieved reasonable control on distribution of preform part materials, obtained optimized pre-forging and roll forging blank and finally obtained finishing forgings of connecting rods with full filling, small trimming and free of forming defect. The established method could achieve good perform optimization design of complex forgings.