旋耕刀辊锻成形工艺的数值模拟与试验验证

Numerical simulation and test verification on roll forging technology for rotary blade

由于辊锻过程中的金属流动和变形规律还未被完全掌握,工艺设计主要依靠生产经验,坯料形状及尺寸选取的是否合理对辊锻件影响较大.以某新型号的旋耕刀为例,依靠经验设计3种不同形状、尺寸的坯料,并利用有限元软件Deform-3D对旋耕刀进行辊锻模拟,选取了合理的坯料,分析了辊锻过程中的金属流动规律,研究了辊锻模具的受载荷情况以及辊锻力矩.根据模拟结果,对所设计的坯料的形状和尺寸进行修正,并进行了生产试制.试制的样品与模拟结果基本一致,表明有限元模拟可以为旋耕刀的辊锻工艺以及坯料选择提供有效的参考.

The metal flow and deformation rules in the roll forging process have not been fully mastered,and the process design mainly de-pends on the experience. Thus,the selection of shape and size for billet has a great influence on the roll forging products. For a new type of rotary blade,three kinds of billets with different shapes and sizes were designed by experiences, and the roll forging process of rotary blade was simulated by the FEM soft Deform-3D. Then,a reasonable billet was selected,and the metal flow rule during the roll forging process was analyzed. Furthermore,the load of roll forging dies was studied and the torque of roll forging was calculated. According to the results of simulation,the designed shape and size of billet were revised,and then the trial sample of rotary blade was manufactured,which was consistent with the simulation results. The result shows that the numerical simulation offers an effective reference for the roll forging process and billet selection of rotary blade.