盘式转向节锻造工艺优化与过程模拟分析

Forging process optimization and process simulation analysis on disc steering knuckle

某型汽车盘式转向节锻造过程中存在高裂纹率(10.00%)、高废品率(7.36%)的质量问题,经分析,由于原锻造工艺设计缺陷,导致易产生锻造折叠、裂纹和充不满模腔等缺陷。因此,开展锻造工艺优化,包括锻件工艺分析、绘制锻件图、选择设备吨位、锻造工艺工步优化、坯料设计和选定、热锻模模具优化设计等。设计两组工艺优化方案:方案1,下料(尺寸为Φ150 mm×280 mm)—镦粗(镦粗量为20 mm)—预锻(料段横放型腔)—终锻—切边;方案2,下料(尺寸为Φ150 mm×280 mm)—镦粗(镦粗量为50 mm)—预锻(料段立放型腔)—终锻—切边。结合有限元过程模拟,对比分析两种工艺方案的模拟质量结果,优化工艺方案。通过过程模拟结果和小批量试制验证对比证明:两组工艺优化方案得到的产品质量较原生产工艺均有所改善,其中方案2的效果更好,锻后废品率由原生产工艺的约7.36%降低至约1.01%,可优先考虑;与实际试制结果对比,过程模拟结果与实际基本吻合,具有可信性。最后,提出了一种理想工艺方案,作为未来锻造技术量产化开发和突破的研究方向。

During the forging process of a certain type of automobile disc steering knuckle,there are quality problems such as high crack rate of 10.00%and high scrap rate of 7.36%.After analysis,due to the design defects of the original forging process,defects such as forging folds,cracks and insufficient filling of mold cavity are prone to occur.Therefore,it was necessary to carry out forging process optimization,including forging process analysis,drawing of forgings diagram,equipment tonnage selection,forging process step optimization,blank design and selection,hot forging mold optimization design,etc.Then,two groups of process optimization schemes were designed,scheme 1 was blanking(size of Q150 mmx280 mm)-upsetting(upsetting amount of 20 mm)-pre-forging(material section placed horizontally in the cavity)-final forging-trimming,and scheme 2 was blanking(size of@150 mmx280 mm)-upsetting(upsetting amount of 50 mm)-pre-forging(material section placed vertically in the cavity)-final forging-trimming.Furthermore,combined with the finite element process simulation,the simulation quality results of the two process schemes were compared and analyzed,and the process schemes were optimized.The comparison between results of process simulation and small batch trial production verification proves that the quality of the products obtained by the two groups of process optimization schemes improves compared with the original production process.The effect of scheme 2 is better,and the scrap rate after forging is reduced from about 7.36%of the original production process to about 1.01%,which is given priority.Compared with the actual trial production results,the process simulation results are basically consistent with the actual situation,which is credible.Finally,an ideal process scheme is proposed as a research direction of mass production development and breakthrough of forging technology in the future.