基于负公差设计的卡车前轴成形工艺改进

Improvement of forming process of truck front axle based on negative tolerance design

以某重型前轴为研究对象,针对现有锻造成形时材料利用率较低、成形载荷较大的问题,对成形工艺进行改进,以此来降低成形载荷,减少材料及能源消耗。对前轴进行工艺分析、计算和有限元模拟;在原有工艺上选择合适规格尺寸的毛坯,采用负公差设计优化前轴精密辊锻工艺,合理分配辊锻毛坯金属。对改进后的工艺方案进行了有限元模拟与物理实验,得到充型饱满、飞边均匀的锻件。改进后的成形工艺比原有工艺终锻成形载荷降低46. 4%,材料利用率由85%提升至92%,同时也改善了金属流动,提高了模具及设备的使用寿命,给企业带来可观的经济效益。

Taking a heavy-duty front axle as the case,focusing on the problems of low material utilization and large forming load in the existing forging process,the forming process was improved to reduce forming load and material and energy consumption.The process analysis,calculation and finite element simulation were conducted on front axle.The blank with appropriate size was selected based on the original process,the precision roll forging process of front axle was optimized by using the negative tolerance design,and the roll forging blank metal was distributed reasonably.The finite element simulation and physical experiment were carried out on the improved process,and the forgings with full filling and uniform flange were obtained.The forging load of the improved process is 46.4%lower than that of the original process,and the material utilization ratio is improved from 85%to 92%.At the same time,the metal flow and the service life of die and equipment are improved,which brings considerable economic benefits to enterprises.