DEFORM-3D在整体辗钢车轮预锻模具型腔分析中的应用

Application of DEFORM-3D in cavity analysis of pre-forging mold for integral steel wheel

依据某840D型车轮产品结构图设计了3种不同方案的预锻模具,并使用塑性精锻有限元软件DEFORM-3D,对该车轮的预锻和精锻工序进行数值模拟,通过对比分析模拟结束后车轮的等效应变、等效应力、温度以及模具的填充性,来讨论3种不同方案模具型腔设计的合理性。结果表明:第3种设计方案中车轮的等效应变满足大于0.69~1.10的要求;最大等效应力为409 MPa,并且除了轮毂部位之外其余部位的等效应力均比较小,优于其他方案;锻件的主要温度分布区间为1100~1240℃且温度分布比较均匀;金属流动均匀性优于其余两种方案。结合现场试验数据修正后,所做的工作对现场具有一定的参考作用。

Three different pre-forging molds were designed according to product structure drawing of a 840 D type wheel,and the pre-forging and precision forging processes of wheel were simulated by finite element software DEFORM-3 D for plastic precision forging.Then,by comparing and analyzing equivalent strain,equivalent stress,temperature and mold filling of wheel after simulation,the rationality of mold cavity design for the three different schemes was discussed respectively.The results show that the equivalent strain of wheel in the third scheme meets the requirements of the equivalent strain greater than 0.69-1.10,the maximum equivalent stress is 409 MPa,and the equivalent stresses of other parts except the hub part are smaller,which is better than other schemes.Furthermore,the main temperature distribution range of forgings is 1100 ~ 1240 ℃,the distribution of temperature is relatively uniform,and the uniformity of metal flow is better than that of the other two schemes.After combining with the correction of field test data,the work done has a certain reference effect on the field.