基于分流特性的H型截面长轴类锻件毛坯精确设计方法

A precise design method for billet based on split-flow characteristics of long axis forgings with H-shape section

分析了长轴锻件H型截面在锻造过程中的材料分流规律,发现由于分流线两侧接触边界条件的变化,分流线两侧面积比的变化可分为5个阶段。基于主应力法分析建立了不同接触边界条件下的分向流动计算模型,可根据H型截面两侧的充填状态计算确定分流线的位置。进一步根据分流规律建立了分流填充模型,能够计算出不同分流状态下的分流线两侧体积分配量。基于上述模型,通过迭代调整毛坯中心位置和求解H型截面两侧型腔充填情况,逐步优化出最佳的毛坯中心位置,可达到两侧筋部同时充满的效果,并提高材料利用率。以某型号控制臂锻件为具体对象,验证了新方法的准确性。

The material split-flow law in forging process of long axis forgings with H-shape section was analyzed. It is found that the change of area ratio between two sides of split line can be divided into five stages due to varied contact conditions. Based on principle stress method,a series of calculation models for split-flow under different contact conditions were established to determine the locations of the split line. According to the split-flow law,the material split-flow filling models in the whole forming process were also established,which were able to calculate volumes of two sides of split line under different conditions. Based on the above models,the optimum center position of the billet axis was gradually optimized by iterative adjusting center position and calculating volume distribution to ensure that both sides of the section were simultaneously filled,which resulted in high utilization ratio of the material. The accuracy of the new method was verified by taking certain type knuckle control arm forging as the concrete object.