基于AFDEX的铝合金车轮锻造缺陷预测与模具优化

Prediction of forging defects and mold optimization for aluminum alloy wheels based on AFDEX

锻造铝合金车轮尺寸较大,外形复杂,加工精度高,模具参数对锻件质量影响较大。在某商用车锻造铝合金车轮的模具开发阶段,使用AFDEX数值模拟软件,预测了铝合金车轮在实际生产中可能出现的缺陷;通过对锻件成品进行宏观组织观察及低倍组织分析,证明预测的缺陷的确存在;并通过优化模具凸起圆角,将凸起圆角由R6 mm调整为R40 mm,有效缓解了金属的回流现象,解决了折叠问题,与模拟预测结果一致;模拟后吨位为7197 t,实际吨位为6600 t,误差约为7%,在合理可控范围内。通过利用AFDEX数值模拟技术预测产品的性能,控制了研发成本,缩短了产品开发周期,也为其他产品开发提供了经验。

Forged aluminum alloy wheels are generally of large size,complex shape and high processing accuracy,so the parameters of mold have a great influence on the quality of forgings. In the early stage of mold development for forging aluminum alloy wheels of a commercial vehicle,the possible defects of aluminum alloy wheels in the actual production was predicted by numerical simulation software AFDEX. Then,the predicted defects are confirmed by macrostructure observation and microstructure analysis of forged products,and the phenomenon of metal backflow is effectively avoided by optimizing the die fillet radius from R6 mm to R40 mm. Thus,the problem of folding is solved,and the actual results are consistent with the simulation prediction results. After the simulation,the tonnage is 7197 t,while the actual tonnage is 6600 t,and the error between them is about 7% which is within a reasonable and controllable range. Thus,the finite element numerical simulation AFDEX is adopted to predict the product performance which can control the research costs and shorten the product development cycle. At the same time,it also provides references for other product development.