斜盘式压缩机双向活塞的锻造工艺及其结构优化

Forging process and structural optimization on bidirectional piston of swash plate compressor

设计了斜盘式压缩机双向活塞的锻造模具及其成形工艺,分析了活塞在压缩机实际运行中的受力情况。应用Ansys Workbench软件对锻造铝合金活塞进行有限元分析,根据数值模拟结果采取增大开裆过渡圆角的措施对活塞进行结构优化。最后,通过生产试制及极限试验验证了锻造模具及其工艺的合理性。结果表明:结构优化后的活塞中部开裆台阶处的最大应力从15.9 MPa变为14.2 MPa,应力减少了10.69%,改进效果显著。经过生产试制和方案修正,成形效果良好,力学性能满足图纸要求。经低倍组织观察流线均匀,晶粒较细,无金属夹杂、裂纹等缺陷;在装机极限试验中活塞运行良好,说明改进后的锻造模具和工艺达到了预期的效果。

Forging mold and forging process on bidirectional piston of swash plate compressor were designed,and the force condition of piston in the actual operation of compressor was analyzed.Then,the forging aluminium alloy piston was analyzed by software Ansys Workbench,and according to the numerical simulation results,the structure of piston was optimized by increasing the opening crotch section transition fillet.Finally,the rationality of forging mold and its process was verified by trial production and limit test.The results show that the maximum stress at step of opening crotch in the middle of piston changes from 15.9 MPa to 14.2 MPa after structure optimization,and the stress is reduced by 10.69%to obtain the remarkable effect.Furthermore,after trial production and scheme modification,the forming effect is good,and the mechanical properties meet the requirements of the drawing.Through macrostructure observation,the streamline is uniform,the grain is fine,and there are no metal inclusions,cracks and other defects.Thus,the piston runs well in the installation limit test,which shows that the improved forging mold and its process achieve the expected effect.