万向联轴器法兰叉头的闭式模锻工艺

Closed die forging process on flange fork for universal coupling

以某型号万向联轴器法兰叉头为研究对象,针对铸造工艺引起的内部组织疏松,造成零件质量不稳定的问题,提出采用闭式模锻工艺的生产方式。采用Deform-3D对闭式模锻过程进行了仿真,观察了成形时金属的填充过程以及成形力的变化过程,并分析了不同坯料高径比及锻压速度对法兰叉头成形质量及成形力大小的影响。模拟结果表明:采用闭式模锻工艺,能够获得填充饱满的法兰叉头锻件;当坯料高径比为0.96、锻压速度为15 mm·s^(-1)时,获得的锻件质量更好,所需的成形力也更小。最后,基于模拟结果,设计了锻造模具,进行了锻造试验,对闭式模锻工艺的合理性进行了验证。

For the flange fork of a universal coupling,the product method of closed die forging process was put forward to solve the problems of loose internal structure and unstable part quality caused by casting process.Then,the closed die forging process was simulated by Deform-3D,the metal filling process and the change process of forming force during forming were observed,and the influences of different blank height-diameter ratios and forging speeds on the forming quality and forming force of flange fork were compared.The simulation results show that the flange fork forgings with full filling can be obtained by closed die forging process.In addition,when the blank height-diameter ratio is 0.96 and the forging speed is 15 mm·s^(-1),the forgings quality is better and the forming force is smaller.Finally,based on the simulation results,the forging die was designed,and the forging test was carried out to verify the rationality of the closed die forging process.