末端法兰热锻成形的数值模拟及工艺优化

Numerical simulation and process optimization on hot forging for terminal flange

针对末端法兰一次终锻成形出现的折叠缺陷问题,分析缺陷形成的原因,并基于Deform-3D有限元分析软件模拟末端法兰成形过程,结合正交试验优化工艺参数,提出制坯、预锻、终锻3步成形方法,调整坯料尺寸、摩擦系数、下压速度及终锻飞边厚度,有效地减小了锻件下模边缘、中孔和凸台的折叠角度,降低了开裂风险,最终锻出合格锻件。试验结果表明：当工艺参数满足坯料直径Φ50 mm、长190 mm、摩擦系数0.25、下压速度60 mm·s^-1、预锻飞边4 mm、终锻飞边3.8 mm,并采用制坯-预锻-终锻3步成形方案时,锻件质量较优。通过实际生产验证了数值模拟结果的准确性和可靠性,获得了符合要求的产品。

For the problem of folding defect of the terminal flange in final forging,the reason of defect formation was analyzed. According to a finite element analysis by software Deform-3 D,the forming process of the terminal flange was simulated,and the three-step forming method of blanking,pre-forging and final forging were proposed by orthogonal test to optimize the process parameters. Then,the blank size,friction coefficient,pressing speed and final forging flash thickness were adjusted,the folding angles of die edge,middle hole and boss were reduced effectively,and the risk of cracking was reduced. Finally,the qualified forgings were obtained. The result shows that when the parameters with blank diameter of Φ50 mm,length of 190 mm,friction factor of 0. 25,pressing speed of 60 mm·s-1,preforging flash thickness of 4 mm,final forging flash thickness of 3. 8 mm are chosen,the forging quality is better by adapting the scheme of blanking-pre-forging-final forging. Eventually,the accuracy and reliability of the simulation results are verified through the actual production,and the requirements of the product are met.