基于有限元铝合金复杂精密锻造模具失效分析及优化

Failure analysis and optimization on aluminum alloy complex precision forging mold based on finite element

针对6082铝合金内扣式消防接口成形过程中精锻模具失效的问题,考虑模具材料和热处理影响,采用试验法对比分析了模具材料和显微结构,并提出了模具结构和模具应力是导致模具失效开裂的主要原因。利用有限元分析法,建立了坯料和模具之间的本构关系,模拟了实际产品成形过程,对产品精锻模具进行了失效分析。通过对模具失效位置的应力进行分析,提出了模具结构的优化方案。试验结果表明,优化后模具失效开裂部位应力集中的现象得到了改善,模具最大应力值由1020 MPa降至800 MPa。采用优化后的模具进行实际生产,模具使用寿命由500件提升至3000余件,并且模具表面磨损较轻,磨损处简单修复后可继续使用,有效地降低了模具成本,为铝合金精密成形的开发和模具寿命的提高提供了理论基础。

In view of the problem of precision forging mold failure in the forming process of 6082 aluminum alloy inner buckle fire protection interface,considering the influence of mold material and heat treatment,the material and microstructure of mold were compared and analyzed by experimental method,and it was found that the mold structure and mold stress were the main causes of mold failure and cracking.Then,the constitutive relationship between billet and mold was established by finite element analysis method,the forming process of the actual product was simulated,and the failure of the precision forging mold for product was analyzed.Furthermore,by analyzing the stress of the failure position for mold,the optimization scheme of the mold structure was proposed.The experiment results show that the phenomenon of stress concentration in the failure cracking positions of the mold is improved after optimization,and the maximum stress of the mold is reduced from 1020 MPa to 800 MPa.The optimized mold is carried out for the actual production,the service life of the mold is increased from 500 pieces to more than 3000 pieces,the surface wear of the mold is light,and the worn part can be used after simple repair,which effectively reduces the cost of the mold.Thus,the research provides a theoretical basis for the development of aluminum alloy precision forming and the improvement of mold service life.