锤头入口曲面对旋锻加工工件变形特性的影响

Effect of hammer inlet surface on deformation characteristics of rotary forged workpiece

为探究旋锻过程中锤头入口曲面变化对工件变形的影响,采用有限元法模拟了含芯棒轴类零件的旋锻加工过程,重点分析了旋锻过程中在具有不同入口曲面的锤头锻打下工件塑性变形时金属的流动及应力-应变分布。以某电动汽车电机轴为研究对象,建立了旋锻加工电机轴的三维模型,对电机轴旋锻过程中的某一道次进行了数值模拟。结果表明,锤头入口曲面的变化对中性面位置、锻透性及应力-应变分布有较大影响;随着锤头阶梯角度的减小,中性面位置逐步向出口端移动,改善了工件的金属流动状况;锻造区内工件所受径向应力增大,材料塑性变形程度增加,工件径向流动增大,提高了锻件的锻透性。

To explore the influence of the change of hammer inlet surface on the deformation of workpiece in the rotary forging process,the rotary forging machining process of shaft parts with mandrels was simulated by finite element method,and the metal flow and stress-strain distribution of workpiece during the plastic deformation with different hammer inlet surfaces in the rotary forging process was analyzed emphatically.Taking an electric vehicle motor shaft as the research object,the three-dimensional model of rotary forging machined motor shaft was established,and a certain pass in rotary forging process of motor shaft was simulated numerically.The results show that the change of hammer inlet surface has a great influence on the position of neutral surface,forging penetration efficiency and stress-strain distribution.With the decrease of step angle of hammer,the position of neutral surface gradually moves to the outlet,which improves the metal flow condition of workpiece.The radial force of workpiece in forging zone increases,the plastic deformation degree of material increases,and the radial flow of workpiece increases,which improves the forging penetration property of forging.